Ransburg REA-90 Service Manual Download

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SERVICE MANUAL
AH-94-04.5

AH-94-04.5

AH-94-04.5
(Replaces AH-94-04.4)

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 this

starting on page 1, and all instructions in this

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

manual. Keep this Service Manual for future

manual. Keep this Service Manual for future
reference.

reference.

Service Manual Price: $30.00 (U.S.)

REA-90 and REA-90L

ELECTROST

ELECTROSTA

ATIC SPRA

TIC SPRA

TIC SPRAY

Y GUNS

GUNS

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)

Summary of Contents for REA-90

Page 1: ...ice Manual Price 30 00 U S Service Manual Price 30 00 U S Service Manual Price 30 00 U S Service Manual Price 30 00 U S Service Manual Price 30 00 U S REA 90 and REA 90L REA 90 and REA 90L REA 90 and...

Page 2: ...n changed from revision AH 94 04 4 AH 94 04 4 AH 94 04 4 AH 94 04 4 AH 94 04 4 to revision AH 94 04 5 AH 94 04 5 AH 94 04 5 AH 94 04 5 AH 94 04 5 Reasons for this change are noted under Manual Change...

Page 3: ...E FITTING INSTALLATION AIR HOSE FITTING INSTALLATION PAINTPREPARATION SPRAY TECHNOLOGY CONVERSION PROCEDURE SPRAY PATTERN ADJUSTMENT GUN TO TARGET DISTANCE AIR CAP FLUID NOZZLE SELECTION CHART AIR CAP...

Page 4: ...PENDIX APPENDIX 73 76 73 76 73 76 73 76 73 76 PAINT AND SOLVENT SPECIFICATIONS VISCOSITY CONVERSION CHART VOLUMETRIC CONTENT OF HOSE OR TUBE 73 74 76 MAINTENANCE continued MAINTENANCE continued MAINTE...

Page 5: ...the proce A NOTE is information relevant to the proce A NOTE is information relevant to the proce A NOTE is information relevant to the proce dure in progress dure in progress dure in progress dure i...

Page 6: ...kept at the rates required by NFPA 33 OSHA and local codes In addition ventilation must be maintained during cleaning operations using flammable or combus tible solvents Electrostatic arcing must be...

Page 7: ...thin the sparking distance 3 3 3 3 3 Explosion Explosion Explosion Explosion Explosion Hazard Hazard Hazard Hazard Hazard Incompatible Incompatible Incompatible Incompatible Incompatible Materials Mat...

Page 8: ...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 9: ...wer supply out so that it cannot be turned ON until the work is fin ished Whenever removing high voltage cables from equipment ground the contact end of the cable by holding the cable such that the co...

Page 10: ...g 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 Workingincoldtemperatures Ris...

Page 11: ...AH 94 04 5 REA 90 and 90L Spray Guns Safety 7 7 7 7 7 NOTES NOTES NOTES NOTES NOTES...

Page 12: ...spray particles under the influence of the electrostatic field be come electrically charged The charged par ticles are attracted to and deposited on the tar INTRODUCTION INTRODUCTION INTRODUCTION INTR...

Page 13: ...R N I N G W A R N I N G W A R N I N G REA 90 WITH A REA 90 WITH A REA 90 WITH A REA 90 WITH A REA 90 WITH AVIA VIA VIA VIA VIAT T T T TOR OR OR OR ORTM TM TM TM TM The REA 90 may be used with the AVI...

Page 14: ...VENT BASE BASE BASE BASE BASE REA 90 ST REA 90 ST REA 90 ST REA 90 ST REA 90 STANDARD ANDARD ANDARD ANDARD ANDARD SPECIFICA SPECIFICA SPECIFICA SPECIFICA SPECIFICATIONS TIONS TIONS TIONS TIONS 75979 S...

Page 15: ...90 and REA 90L Standard AVIATOR 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 Gun Fe...

Page 16: ...A ATERBORNE TERBORNE TERBORNE TERBORNE TERBORNE REA 90 ST REA 90 ST REA 90 ST REA 90 ST REA 90 STANDARD ANDARD ANDARD ANDARD ANDARD SPECIFICA SPECIFICA SPECIFICA SPECIFICA SPECIFICATIONS TIONS TIONS T...

Page 17: ...REA 90 and REA 90L Standard AVIATOR Waterborne Figure 2 REA 90 and REA 90L Standard AVIATOR Waterborne Figure 2 REA 90 and REA 90L Standard AVIATOR Waterborne Electrostatic Spray Gun Features Electros...

Page 18: ...ion of Control Unit Location of Control Unit Location of Control Unit Location of Control Unit Location of Control Unit A A A A AVIA VIA VIA VIA VIAT T T T TOR Units OR Units OR Units OR Units OR Unit...

Page 19: ...tall an air filter assembly on the air inlet of the control unit Screw the fitting into the filter inlet The filter MUST be installed with the arrow pointing in the direction of flow Refer to the appr...

Page 20: ...n and off and explosion proof in dicator light indicates status of control unit within the hazardous area for the convenience of the operator Location of Control Unit Location of Control Unit Location...

Page 21: ...s moisture and is a poor insulator Electrical current passing through these materials can ignite them causing a hazardous condition C A U T I O N C A U T I O N C A U T I O N C A U T I O N C A U T I O...

Page 22: ...end of the fluid hose by turning the nut of the male connector counterclockwise while holding its main body 2 Remove the male connector nut from the fluid hose 3 Determine the hose length that is need...

Page 23: ...to the appropriate fluid source The union stem will not seat if the hose is bottomed against the ferrule NOTE NOTE NOTE NOTE NOTE Figure 4 Fluid Hose Assembly Figure 4 Fluid Hose Assembly Figure 4 Flu...

Page 24: ...es and test nozzles are available to confirm the pressure output See Service Kits Figure 32 for these parts NOTE NOTE NOTE NOTE NOTE 1 Remove the existing retaining ring and air nozzle from the gun 2...

Page 25: ...the spray pattern axis of fan atomizers from horizontal to vertical loosen the retainer ring rotate the air cap clockwise to the desired position and gently tighten the ring A counterclockwise turn o...

Page 26: ...Air Cap Air Cap Air Cap Air Cap Air Cap Part Part Part Part Part Orifice I D Orifice I D Orifice I D Orifice I D Orifice I D Fluid Nozzle Fluid Nozzle Fluid Nozzle Fluid Nozzle Fluid Nozzle Part Part...

Page 27: ...300 318 Spray Spray Spray Spray Spray Type Type Type Type Type Air Spray Air Spray HVLP Spray Air Air Air Air Air Consumption Consumption Consumption Consumption Consumption SCFM SCMM SCFM SCMM SCFM...

Page 28: ...damage to the components W A R N I N G W A R N I N G W A R N I N G W A R N I N G W A R N I N G SUIT SUIT SUIT SUIT SUITABLE SOL ABLE SOL ABLE SOL ABLE SOL ABLE SOLVENTS VENTS VENTS VENTS VENTS FOR CLE...

Page 29: ...T I O N C A U T I O N C A U T I O N C A U T I O N C A U T I O N Clean all insulating surfaces in the system Remove paint accumulation from the exterior of the gun and low voltage cable with a solvent...

Page 30: ...solids The paint being used and the length of downtime will determine the need for flush ing Metallic paint and primer will require flushing sooner than other types of coating materials NOTE NOTE NOTE...

Page 31: ...ection for disassembly procedures NEVER NEVER NEVER NEVER NEVER wrap the applicator associated valves and tubing and supporting hardware in plastic to keep it clean A surface charge may build up on th...

Page 32: ...rench 19749 00 3 32 inch Allen Wrench for Set Screws 2 3 16 inch Allen Wrench for Hose Fittings Open End Wrenches 15 16 7 8 11 l6 9 16 7 16 3 4 3 8 and 1 4 inch Screwdriver blade Dielectric Grease LSC...

Page 33: ...C A U T I O N C A U T I O N C A U T I O N C A U T I O N C A U T I O N Figure 7 Solvent Base Gun Connections Figure 7 Solvent Base Gun Connections Figure 7 Solvent Base Gun Connections Figure 7 Solvent...

Page 34: ...luid hose assembly out of the barrel removing the spacer ferrule and fluid tube connector Then continue pull ing the fluid hose assembly through the bracket removing the fluid tube nut con ductive fer...

Page 35: ...position Figure 9 Air Cap Fluid Nozzle Nut Figure 9 Air Cap Fluid Nozzle Nut Figure 9 Air Cap Fluid Nozzle Nut Figure 9 Air Cap Fluid Nozzle Nut Figure 9 Air Cap Fluid Nozzle Nut 1 Retaining Nut 2 Ai...

Page 36: ...g so could damage or break the fluid nozzle or damage the thread of the barrel NOTE NOTE NOTE NOTE NOTE NEEDLE ELECTRODE NEEDLE ELECTRODE NEEDLE ELECTRODE NEEDLE ELECTRODE NEEDLE ELECTRODE Removal Rem...

Page 37: ...he retaining nut completely and remove the air cap 3 Using a flat head screwdriver remove the two shoulder screws that retain the trigger to the gun handle 4 While holding the grounding spring lo cate...

Page 38: ...spring loaded u cup and o ring can now be removed from the rear seal retainer During this operation be CAREFUL that the interior surface of packing chamber is NOT damaged marred or scratched This cham...

Page 39: ...the front of the needle shaft Then screw it on and over the ex ternal threads of the needle shaft Once both internal o rings have cleared the threads slide it onto the sealing area Do NOT push the ca...

Page 40: ...the hexagon forward Do not lock the hexagon nuts in place 11 Install the needle shaft subassembly into the packing chamber from the rear of the barrel with the needle electrode forward 12 Push the ne...

Page 41: ...ge hole of the gasket over the needle shaft and onto the boss of the barrel packing chamber 5 While holding the barrel with the air nozzle pointing downward install the needle shaft spring into the sp...

Page 42: ...r ad justment and can be altered to obtain proper triggering sequence NOTE NOTE NOTE NOTE NOTE 7 Check the spacing between the back of the spring retainer and the handle It should be about 1 8 inch If...

Page 43: ...Cable Plug Assembly Test The hook transformer can be tested using the Transformer Output Tester and following the guidelines of it s instruction manual TE 88 02 If the transformer out put tester is no...

Page 44: ...ormers Figure 19 Hook Transformers Figure 19 Hook Transformers Figure 19 Hook Transformers Switch Position Switch Position Switch Position Switch Position Switch Position Replace LED Lens Replace LED...

Page 45: ...ble and must be re placed Reinstall Reinstall Reinstall Reinstall Reinstall 1 Apply a light coating of dielectric grease to the on off switch 2 With the hook transformer setting with the set screw fac...

Page 46: ...l from Service Removal Fluid Tube and Fluid Hose for Solvent Base Guns or Fluid Hose for Waterborne Guns Removal Air Hose Removal Low Voltage Cable Removal Low Voltage Cable Plug Assembly Removal Trig...

Page 47: ...ry C A U T I O N C A U T I O N C A U T I O N C A U T I O N C A U T I O N 4 Remove the spring from the control knob stem 5 Unscrew the control knob and pull it out of the retaining nut 6 With a small r...

Page 48: ...he back of the air valve rod assembly 4 From the front of the handle push the air valve rod assembly rearward until it can be removed by hand from the back of the handle Do not use any tools to Do not...

Page 49: ...retaining nut cannot be reused once it has been removed from its holder C A U T I O N C A U T I O N C A U T I O N C A U T I O N C A U T I O N TRIGGER TRIGGER TRIGGER TRIGGER TRIGGER Removal Removal R...

Page 50: ...the barrel forward until there is enough clearance between the needle shaft spring retainer and the handle to remove the spring 3 Insert the shoulder screws through the holes of the trigger and screw...

Page 51: ...the low voltage cable plug assembly from the handle will damage the low voltage plug assembly and the hook transformer If this occurs both components have to be replaced C A U T I O N C A U T I O N C...

Page 52: ...A R N I N G W A R N I N G W A R N I N G W A R N I N G 2 If the low voltage cable assembly has not been tested it should be tested Refer to Low Voltage Control Unit Test Assembly manual TE 96 01 3 The...

Page 53: ...vice No attempt should be made to clean the inside diameter of the fluid tube once it is removed from the gun If there is paint residue in the bore it should be replaced Also if the outer sur face is...

Page 54: ...e the fluid tube to the barrel using a wrench 5 Flex the fluid tube slightly until the other end fits into the fitting on the fluid tube bracket If the fluid tube will not flex enough loosen the fitti...

Page 55: ...uid Hose Fitting Item Item Item Item Item Description Description Description Description Description Figure 26 Proper Position Figure 26 Proper Position Figure 26 Proper Position Figure 26 Proper Pos...

Page 56: ...BRACKET FLUID TUBE BRACKET Removal Removal Removal Removal Removal 1 For solvent base guns solvent base guns solvent base guns solvent base guns solvent base guns remove the fluid tube Refer to Fluid...

Page 57: ...ure 15 3 Normally if this distance is correct the mechanical sequence will function prop erly If not check the assembly for problems such as a missing gasket loose fluid nozzle loose needle elec trode...

Page 58: ...up For additional information on adjusting the spray pattern refer to REA Handgun Spray Techniques manual IL 246 FLUID DELIVERY FLUID DELIVERY FLUID DELIVERY FLUID DELIVERY FLUID DELIVERY ADJUSTMENT A...

Page 59: ...2 Replace Pattern Heavy at One Pattern Heavy at One Pattern Heavy at One Pattern Heavy at One Pattern Heavy at One End End End End End 1 Clogged or faulty air cap 2 Clogged or faulty fluid nozzle 1 Cl...

Page 60: ...EAKAGE LEAKAGE LEAKAGE LEAKAGE ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL ELECTRICAL Wrap Back Wrap Back Wrap Back Wrap Back Wrap Back 1 Impropertargetground 2 Improperspraytechnique 3 Improperboothe...

Page 61: ...ed Continued Continued Improper or No High Improper or No High Improper or No High Improper or No High Improper or No High Voltage Voltage Voltage Voltage Voltage Continued 7 Check fuses 8 Is the powe...

Page 62: ...e 29a 75785 Solvent Base Standard and 75979 Solvent Base AVIATOR MGS Figure 29a 75785 Solvent Base Standard and 75979 Solvent Base AVIATOR MGS Figure 29a 75785 Solvent Base Standard and 75979 Solvent...

Page 63: ...rigger 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 VENT B...

Page 64: ...rrel REA 90 75791 00 5 Reducer Pressure Air Spray Black 74963 02 6 Reducer Pressure HVLP White 74963 03 7 Nut Retainer Barrel 75323 00 8 Ring Retaining Barrel 75326 00 9 Electrode Assembly 70430 00 10...

Page 65: ...04 16 For 70441 00 45o Bracket 093 I D 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 Bra...

Page 66: ...n Description Description Description REA 90 90L REA 90 90L REA 90 90L REA 90 90L REA 90 90L SPRA SPRA SPRA SPRA SPRAY Y Y Y Y GUNS 75785 75979 P GUNS 75785 75979 P GUNS 75785 75979 P GUNS 75785 75979...

Page 67: ...AH 94 04 5 REA 90 and 90L Spray Guns Parts Identification 63 63 63 63 63 NOTES NOTES NOTES NOTES NOTES...

Page 68: ...Standard and 75982 Waterborne AVIATOR Figure 29b 75786 Waterborne Standard and 75982 Waterborne AVIATOR Figure 29b 75786 Waterborne Standard and 75982 Waterborne AVIATOR Figure 29b 75786 Waterborne St...

Page 69: ...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 90 A...

Page 70: ...A 90 75791 00 5 Reducer Pressure Air Spray Black 74963 02 6 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 Se...

Page 71: ...d 76993 00 61 Ferrule 72308 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 Connec...

Page 72: ...P PAR AR AR AR ARTS LIST TS LIST TS LIST TS LIST TS LIST BULLET BULLET BULLET BULLET BULLET DEFINITION T DEFINITION T DEFINITION T DEFINITION T DEFINITION TABLE Figure 29b ABLE Figure 29b ABLE Figure...

Page 73: ...AH 94 04 5 REA 90 and 90L Spray Guns Parts Identification 69 69 69 69 69 NOTES NOTES NOTES NOTES NOTES...

Page 74: ...p 4904 xx 1 2 3 4 Replace xx with 63 98 or 65R Fluid Nozzle 75600 01 1 2 3 4 For use with HVLP only Air Cap 75601 00 1 2 3 4 For use with HVLP only Air Cap 75756 00 1 2 3 4 For use with HVLP only Cap...

Page 75: ...build Kit Contains the following parts 78929 01 78929 01 78929 01 78929 01 78929 01 Soft Parts Kit 78929 00 1 Supplied Needle Shaft 78627 04 1 Supplied Tube Packing 18842 01 1 Supplied Electrode 70430...

Page 76: ...OBLIGATION ITW RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO RE UNDER THIS WARRANTY IS TO RE UNDER THIS WARRANTY IS TO RE UNDER THIS WARRANTY IS TO RE UNDER THIS WARRANTY IS TO RE PLACE PARTS...

Page 77: ...MAK SC 100 DIBK Amyl Alcohol Butyl Cellosolve SC 150 Chlorinated Solvents Aliphatic Hydrocarbons Ketones Esters Aromatic Hydrocarbons Esters Ketones Esters Alcohols Ketones Alcohols Esters Aromatic Hy...

Page 78: ...2 Zahn 2 Zahn 3 Zahn 3 Zahn 3 Zahn 3 Zahn 3 Zahn 4 Zahn 4 Zahn 4 Zahn 4 Zahn 4 Zahn 5 Zahn 5 Zahn 5 Zahn 5 Zahn 5 Sears Sears Sears Sears Sears Craftsman Cup Craftsman Cup Craftsman Cup Craftsman Cup...

Page 79: ...ic Lithographic Lithographic Krebs Unit Krebs Unit Krebs Unit Krebs Unit Krebs Unit KU KU KU KU KU Saybolt Saybolt Saybolt Saybolt Saybolt Universal SSU Universal SSU Universal SSU Universal SSU Unive...

Page 80: ...7 3 fl oz 102 gal 13 1 fl oz 010 gal 1 2 fl oz 022 gal 2 8 fl oz 038 gal 4 9 fl oz 060 gal 7 6 fl oz 086 gal 11 0 fl oz 153 gal 19 6 fl oz 016 gal 2 0 fl oz 036 gal 4 6 fl oz 064 gal 8 2 fl oz 100 gal...

Page 81: ...AH 94 04 5 NOTES NOTES NOTES NOTES NOTES...

Page 82: ...AH 94 04 5 NOTES NOTES NOTES NOTES NOTES...

Page 83: ...4 REA 90 and 90L Spray Guns to make the following changes 1 Maintenance Maintenance Maintenance Maintenance Maintenance section revised Figure 21 Gun Repair EquipmentRequired Air Valve Removal Cleani...

Page 84: ...istance 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 Telephone 800 233 3...

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