Operation and Maintenance Manual

AUTOMATIC AIR ELECTROSTATIC SPRAY GUN

ROBO GUNⅡ

ＥＡＢ９０

This Instruction Manual contains important warnings and cautions for using
this equipment.
Before using the equipment, please read and understand the contents of
this Manual.
Keep this Manual as long as the equipment is in use. If this Manual is lost
or damaged, ask our distributor or us for a new copy.
 PREFACE
Thank you for your choice of ASAHI SUNAC Automatic air electrostatic spray gun
(EAB90).

In order to ensure long and proper use of this equipment under the most optimum
conditions, please read all the contents of this Manual. You are requested to note
and understand all of the indicated specifications, warnings, prohibitions and cautions
contained in this manual and to use this equipment correctly following these
instructions.

The equipment for which this Manual has been prepared is an apparatus for
professional coating work. The use of this product should only be by personnel who
are well trained in handling and operating this equipment.

If there is anything in this Manual unclear to you, please ask our distributor in or
contact us referring to Model and Serial No. of the equipment in question, for a more
detailed explanation.
Contents

1 FOR SAFETY AND CORRECT USE ·····························１

2 OUTLINE OF THE EQUIPMENT ···································３
3 SPECIFICATIONS ·························································５
4 CAUTIONS BEFORE OPERATION·······························６
5 OPERATION STEPS AND CAUTIONS ·························７
6 MAINTENANCE AND REGULAR CHECKING ··············１０
7 HOW TO REPLACE PARTS··········································１１
8 TROUBLE SHOOTING ··················································１４
9 BREAKDOWN DRAWINGS AND PART LIST ················１６
10 SERVICE RECORD·······················································１７
11 SCOPE OF WARRANTY ···············································１７
 1 FOR SAFETY AND CORRECT USE

It is important to understand and strictly follow all the instructions contained in this Manual for correct use
of the equipment.
Any improper use or if these instructions are ignored, there may be cause for serious injury or damage to
related equipment.

The safety instructions indicated in this Manual are of the least necessity and do not mean that
compliance with only those instructions may be satisfactory. Rules and principles for safety set forth by
your company and local laws, codes and regulations enacted by public authorities must be also followed.

Shown below are the minimum basic safety precautions in connection with use of our product:

●There are three stages in this Manual of important information for safety classified by their degree of
seriousness, as example below.
to bring your attention to the possibility of situations which could cause serious
WARNING: injury or property damage and to suggest methods of prevention.
to bring your attention to the possibility of situations which could cause damage
CAUTION: or breakage of the equipment and to suggest methods of prevention.
to point out important and useful information concerning the use of this
NOTE: equipment.

※ The situations indicated under the mark of CAUTION may cause more serious danger depending on
circumstances, for which your careful attention is requested.

1
 WARNING
<<Range of Application of this equipment>>
This manual is designed specifically for the Robo gun II EAB90 Automatic air electrostatic spray gun.
This product is an automatic spray gun. It is installed on an automatic coating line equipped with
exhaust equipment and is used to spray atomized paint.
Please contact us if you have any questions about the material used as well as about the intended use
of this product.
Use of this product for any other purposes is regarded as improper use, which is prohibited without our
written permission. Please note that improper use of this product could result in major accidents.

<<General precautions when handling the coating equipment>>

(1) Make sure that the work piece subject to coating is constantly grounded. Do NOT use a hanger with
poor conductivity. Clean hangers at regular intervals to maintain their conductivity.
(2) All conductors and thinner containers inside the coating booth must be grounded.
The entire surface of the floor must have a resistance of 1 MΩ or lower to prevent static charge.
Keep it clean and tidy.
(3) Perform operations with bare hands; or wear conductive gloves throughout operations.
(4) Wear antistatic shoes throughout operations.
(5) Keep the room well-ventilated during paint spraying operations.
(6) Before cleaning the nozzle, make sure that the spraying pressure and air pressure readings are

zero (0) and that the power switch on the control panel is OFF.
(7) NEVER use any metal brushes to clean the nozzle.
(8) Do NOT soak the gun, hoses, etc. in thinner.

(9) Do NOT drag the hoses, etc. on the floor. They should be suspended from the ceiling or side wall.
(10) The exhaust system (duct, fan) in the coating booth must always be kept clean; it should be
cleaned at regular intervals.
(11) Make sure that the tip of the nozzle is at least 150 mm away from the work piece subject to paint
spraying.
(12) If an insulating stand is used, it must be located at least 300 mm away from the other objects
around it. Before touching it, turn off the power switch on the power pack and then ground the
insulating stand.
(13) Keep a fire extinguisher handy in case of emergency.

(14) The coating equipment must be operated only by a person that has successfully completed a
safety training program regarding coating equipment.
(15) It objects are metal,Grouding resistance should be under 1kΩ , It objects are plastic,Grouding
resistance should be under 1MΩ.

2
 2 OUTLINE OF THE EQUIPMENT

①Outside Drawing〈EAB90〉

Weight : 1.4kg

Pattern air Cable

Atomizing air
PA
AA

Trigger valve driving air

Paint hose Plug

(Special double tube) (Return path can be added at option)
F.IN F.OUT

②Composition
(1)Gun Main Body
・A Trigger Valve and a Cascade(Electrostatic Generator) are incorporated in this body, which is
covered by a Shroud.
(2)Connecting Cable(10m)
・This Cable connects the Cascade to outside Controller.

3
③Optional Accessories
(1) Air Cap Set
・Please select any of Air Cap Sets according to product to be coated, paint material and required
paint output.
・Take much care in touching Electrode, etc.

(2) Paint Hose

・This Hose is a double tubed hose specially designed for this Gun.
・Additional Hose can be assembled for making circulation or drain path.
(Refer to Art. 7. – 1 “Disassembly of Gun Body’ on this Manual.)
・Please select the type of Paint Supplying Hose and paint Hose according to resistance value of
the paint to be used, insulation type with plastic joint or grounding type with metal joint.

Part No. Name Remarks

3445 Paint Hose Metal joint 1m
3445-1 Paint Hose 5m
3445-2 Paint Hose 10m
3446 Paint Hose Plastic joint 1ｍ
3446-1 Paint Hose 5ｍ
3446-2 Paint Hose 10ｍ

(3) Extension Cable

・If necessary, Extension Cable can be added between Connecting Cable and Electrostatic Controller to
the maximum length of 25m.

Part No. Name Remarks

2549 Extension Cable 10ｍ
2549-1 Extension Cable 20ｍ

(4) Electrostatic Controller

・This Controller is used for supplying power to Cascade in Gun Body and for detecting any error.

Product name Electrostatic controller

Model BPS260
Parts No. 445-0159
Number of connectable guns 2 or less
Output voltage adjustment -20 to -60kV (at intervals of 1kV)
NOTE: For detail, see the Instruction Manual for ｢Electrostatic controller BPS260｣.

(5) Paint Supplying System

Paint supplying system should be arranged according to work conditions (paint type, total system
specifications, etc.). Please refer to our catalogues.

4
④Connection of each component
・Signal input/output to Electrostatic Controller and paths for air and painting material should be
connected separately referring to the sketch shown below.
・Details of connections for power, air and paint should be referred to the specifications of each
system.

Automatic air electrostatic gun Electrostatic controller

Power input
Connecting cable Signal input

Atomizing air AA
Trigger valve Pattern air PA
Cascade
Triggering air TA

Paint feeding F.IN

Paint circulation/Return (Option) F.OUT

CAUTION
Gun Bracket should be fastened to metal support securely grounded sufficiently. . When to
protect the Gun installed on Robot with plastic shear pins, never forget to ground the Gun
Bracket with grounding wire. (Grouding resistance should be under 1kΩ)

3 SPECIFICATIONS

(1) Name ： Automatic air electrostatic spray gun

(2) Model ： EAB90（Part No.137F）
Fluid pressure MAX 0.7MPa
Air pressure MAX 0.7MPa
(3) Paint output ： 500mL／min（MAX）
(4) Incorporated valve ： Trigger valve
(5) Voltage to be changed ： MAX DC-60kV
at output current of 20μA ： －55±3ｋＶ
at max. current of 80μA ： －37±3ｋＶ
(6) Air tube ： for atomizing air ： φ8x6mm 400L/min (normal)（at 0.5MPa）
for pattern air ： φ8x6mm 400L/min (normal)（at 0.5MPa）
for trigger valve air ： φ6x4mm over 0.35MPa
(7) Connecting cable ： 10m、MAX 25m with extension
(8) Required air volume ： Both of atomizing air and pattern air should be compressed air of over 400L/min
(normal) (at 0.5MPa) at gun entrance.
(9) Weight ： 1.4kg

5
 4 CAUTIONS BEFORE OPERATION

This Spray Gun is designed and manufactured taking full consideration of keeping safety, but it should
be handled with much care as it may be used in the place where ignitable gas atmosphere exists.

WARNING
●The product to be coated should be correctly grounded.
(It object is metal : Under 1 kΩ , It object is plastic : Under 1 MΩ.)
Generally, the products to be coated are grounded through conveyer structure but sometimes
conductivity may be prevented by dried paint sticking to the part of hanger touching the
product, resulting in accumulation of electric charge there which may cause sparking and,
then, fire. Hangers should be regularly cleaned by removing the stuck paint.
●All metal articles in Coating Booth should be grounded.
●As high voltage is exposed in the Coating Booth, any non-grounded metal article in it is
electrically charged and may cause sparking and fire.
●Never make the Nozzle at Gun Head contact to the coating object. Incorrect hanging of the
coating object or conveyer’s swinging may make the object come close to the Nozzle causing
sparking and fire. Especially when an Insulation Base is used, greater sparking will occur.
Take sufficient spray distance.
●When to use an Insulation Base, paint supplying system should be placed far over 300mm
from all articles surrounding it. Some paints of low resistance are so conductive as electric
wires and, if any part of your body touches the paint container, there is a danger of electric
shock. Where the coating work place faces to walking passage, a grounded fence should
be provided.
●Operator should put on leather soled shoes or anti-electrostatic shoes having resistance
value of 1MΩ or less. Rubber sole or synthetic resin sole shoes may have a danger of
electric shock when they touch any grounded article.
●Whenever to work with coating operation, air ventilation system should be driven. Since many
paints and solvents are defined as dangerous under Fire Law and the gasses generated by
their spraying are defined as explosive(Grade 1), you are not allowed to use them in
non-ventilated place.
●Do not leave paints or solvents in the Coating Booth. They must be stored in legally
permitted stock house. Especially, any cleaning solvent should be contained in a container
with rigid cap.
●Provide fire extinguisher in coating work place. Powdered carbon dioxide gas extinguisher
will be recommendable.

6
 5 OPERATION STEPS AND CAUTIONS

①Paint
(1) Adjustment of paint Viscosity
In case of electrostatic spray coating, paint should be adjusted at the lower viscosity than in case of
normal air spray. Lower viscosity paint may be easily atomized by lower air pressure which raises
the paint transfer efficiency. Solvent should be the one prepared for electrostatic coating.
Generally, the viscosity should be in the range from 11 to 30 sec. at 18℃ by Asahi Cup.

(2) Start to drive paint Pump (referring to Operation Manual for the Pump)
If any air remains in Paint Hose, paint spray will pulsate causing uneven output. Air in Hose should
be fully excluded.

(3) Adjustment of Paint Output Rate

Turn Work Selection Switch on Control Panel to “MANUAL”, turn Paint On/Off Switch to “ON”, raise
pressure at Air Regulator for Paint Output Adjustment placed on lower surface of Control Panel,
and, making paint outflow from Nozzle, adjust to the required flow rate.
When to use low viscosity paint at lower output rate, the adjustment will be easier by inserting a
Nozzle Seat of small orifice between Gun and Nozzle.
When higher output rate is required, remove the Nozzle Seat and use a Nozzle having larger port.
Air pressure for Paint On/Off Cylinder should be 0.4MPa or more.

②Atomizing Air Pressure

(1) Atomizing air pressure may be pretty lower than for normal air spray.
Higher pressure can make finer paint particles, but results in poor wrap-around and much paint
re-bouncing.

(2) To adjust the atomizing air pressure, turn Work Selection Switch on Control Panel to “MANUAL”,
turn Switch for Atomizing to “ON”, and adjust the pressure by Air Regulator for Atomizing Air placed
on lower surface of the Control Panel, making air outflow from Nozzle.

③Pattern Changing Air Pressure

To adjust the pattern changing air pressure, turn Work selection Switch on Control Panel to “MANUAL”,
turn Switch for Atomizing to “ON”, and adjust the pressure by Air Regulator for Pattern Changing
placed on lower surface f Control Panel, making paint be sprayed out.

④Spray Distance
Distance between Nozzle head and the surface of object should be 150mm or more, and Spray Gun
should be set forwarder than front surface of Reciprocator or Robot
Too far distance will lower the transfer efficiency and too short distance has the possibility of sparking.
The optimum spray distance may be in the range of 150 to 300mm.

⑤Gun Moving Speed

Gun moving speed depends on the required film thickness, but generally may be 15 to 45m per
minute. If the required film thickness can not obtained even at the speed of over 50m per minute,
there will be necessity to increase numbers of Gun or to add paint heater to the system, for which
please consult our Coating Technology section staffs. (Too fast speed is not recommended because it
may lower the paint transfer efficiency.)

7
⑥Operation Steps
(1) Manual Operation
１．Switch on the power source
Set on Breaker in Control Panel and make sure that the Indication Lamp “POWER” is lighted
up. Confirm that Interlocks including Door Switch are in correct condition.
２．Turn Work Selection Switch to “MANUAL”.
Be sure that the Indication Lamp “MANUAL” is lighted up.
３．Turn Work Selection Switch to “SPRAY”.
４．Make atomizing air and pattern changing air start to flow out.
Turn Switch for Atomizing Air to “ON”. Make sure that the Indication Lamp “ATOM.” is lighted
up.
５．Make paint start to flow out.
Turn Switch for Paint to “ON” and confirm that the Indication Lamp “PAINT” is lighted up. Adjust
atomizing air pressure, pattern changing air pressure and paint output by Air Regulators on lower
surface of the Control Panel.
６．Push Switch “START” for Reciprocator.
Make sure that the Indication Lamp “RECIPRO” is lighted up.
７．Supply high voltage.
Turn Switch “POWER” on Controller located at center of front surface of Control Panel and
confirm that the Indication Lamp “POWER”(green) on Controller is lighted up. Then, push
Switch “ON” for High Voltage on upper surface of Control Panel. Confirm that the Indication
Lamp “HIGH VOLTAGE” and Lamp for High Voltage(red) are lighted up.
８．Start coating operation.

(2) Automatic Operation

１．Switch on the power source.
Set Breaker in the Control Panel and make sure that the Indication Lamp “POWER” is lighted
up. In case Door Switch is provided, confirm that the Door is closed.
２．Turn Work Selection Switch to “AUTO”.
３．Turn Work Selection Switch to “SPRAY”.
４．Confirm that the Switch for Atomizing Air is turned to “ON”.
５．Confirm that the Switch for Paint is turned to “ON”.
６．Push Switch “START” for Reciprocator.
Confirm that the Indication Lamp “RECIPRO” is lighted up.
７．Supply high voltage.
Turn Switch “POWER” on Controller to “ON”. Confirm that the Lamp for Power
Source(green) on Controller is lighted up. Then, push Switch “ON” for High Voltage located
on upper surface of Control Panel, and confirm that the Indication Lamp “HIGH VOLTAGE” and
the Lamp(red) for High Voltage on Controller are lighted up.
８．Start coating operation.

⑦Steps at temporary stop or finish of coating work

(1) Nozzle Cleaning
Whenever to stop or finish the coating work, clean Nozzles on Spray Gun.
１．Push Switch “OFF” for High Voltage to cut off high voltage supply.
２．Stop Robot or Reciprocator and stop output of air as well as air.
３．Ground the head of Nozzle to discharge remaining electric charge using grounding bar.
４．With a brush dipped in solvent(made of horse hair or other animal or vegetable hairs), clean the
Nozzle by removing paint sticking to it. If the paint is difficult to be removed, dip the Nozzle in
solvent for several minutes and clean it by brushing.
５．After cleaning, make atomizing air flow out by manual operation to blow out the solvent entering
into air passage.

8
 (2) Cleaning of Paint Hoes, Spray Guns and Paint Regulators
In case of paint color changing or stopping work for a certain long time, all paint passages should
be cleaned.
１．Push Switch “OFF” for High Voltage to cut off the high voltage.
２．Stop Robot or Reciprocator moving, and stop outflow of paint and air.
３．Turn Work Selection Switch to “CLEANING”.
４．Drive paint Pump at non-load by manual operation to remove paint remaining in paint passage.
The time can be shortened by supplying pressurized air. Confirm again that the high voltage
is shut off.
５．Change over the Three-way Cock at Paint Pump to push out any paint remaining in Paint Hoses,
Paint Regulators and Spray Guns. After then, shut the Cock.
６．Move Suction Pipe placed in paint container into solvent container and make the solvent
circulate in paint passage for about 5 minutes without flowing out from Gun Head. This should
be done with clean solvent and repeated 2 or 3 times.
７．If the equipment will be not used for long time, make the cleaning solvent completely flow out or
fill the solvent in the paint passages.
８．Paint or dust contamination on the surfaces of equipment should be wiped off by waste cloth
including solvent. Do not remove Shroud of Spray Gun to clean inside parts with solvent.

⑧Cautions at Operation

WARNING
●Never forget to shut off high voltage whenever to clean Nozzles.
●When to use low resistance paint, use Insulation Base. If not, the electrostatic effect can not be
obtained. Generally, in case of any paint having its resistance value 10MΩ or under and
preset voltage of 60kV, or when ampere meter on Electrostatic Controller shows 70μA or over,
the Insulation Base should be provided for paint supplying System.
●Operator should keep distance at least 1m from spray equipment. Coming close to the
equipment may cause danger of electric shock.
●Do not leave paint or solvent containers in Coating Booth.
●All metal articles in Coating Booth should be grounded.

CAUTION
●As Nozzle is a vital part for spray coating system, much care should be taken not to drop it
down or give it any damage.
●Water accumulated in compressor should be drained once a day. Cartridge elements for air
filter and mist separator should be replaced with new ones regularly once a half year or a
year.
●Painting material should be used after its filtration.
●Do not use Spray Gun without its Shroud.
●In case of use of two component material or any easily depositing paint, clean inside of the
equipment completely with solvent. Incomplete cleaning may cause short life of packing in
valve and, then, fluid leakage.

9
 6 MAINTENANCE AND REGULAR CHECKING

①Maintenance for Nozzles

(1) As a daily maintenance, check if there is paint clogging at Nozzles’ exit openings. Once a month,
remove the Nozzles and clean them to remove paint residue penetrating into air holes.
(2) In case of using two-component paint, the hardened material may stick to Nozzle and there is a
possibility of its breakage if you disassemble it by force. Before starting to use two-component paint,
make sure that the Nozzle is tightened securely and, right after using it, clean it completely with
solvent.

②Maintenance for Automatic Air Electrostatic Spray Gun

(1) Paint or dust sticking to Gun’s body should be wiped off after each coating work with soft brush or
cloth leaving the Shroud be attached to it. Do not clean the Gun body by spraying solvent over it,
as the solvent may penetrate into inside of the Gun by the force of air pressure.

CAUTION
●Solvent penetrating into Gun’s inside may cause over current at electrostatic charging to
prevent electrostatic coating.
●If too much paint sticks to Gun Body, electrostatic may leak through such stuck paint to cause
over-current and, then, deficiency of electrostatic coating.

(2) When to clean the Air Cap or Paint Nozzle leaving the Nozzle attached the Gun, blow out
atomizing air and pattern air after such cleaning, to exclude solvent penetrating into air passages.

CAUTION
●When to clean the Gun installed upright(Gun Head upward), clean it making atomizing air and
pattern air blow under a pressure of approx. 0.05MPa.
●If such conductive paint as metallic penetrates into air passage, electrostatic may leak through
the paint causing over-current and, then, prevent electrostatic coating.

(3) Shroud should be dismantled once a week to check if there is paint or solvent penetration inside.
If paint sticking to inside, remove it with solvent and blow air to eliminate the solvent completely
before assembling the Shroud.
(4) As a daily checking, confirm that there is no damage nor excessive tension on connecting cable to
the Gun.

CAUTION
Connecting Cable is not only for supplying power to the Gun, but also for the purpose of
grounding and control. Use of damaged Cable may cause trouble of fire or electric shock by
failure in grounding.

10
 (5) It should be confirmed daily, before starting operation, that all metal parts such as Gun Fixing
Bracket are securely grounded. Check and confirm that the resistance value between Gun’s
Bracket and such grounded article as Booth construction is 10Ω or under.
(6) Every day, before starting operation, check if there is no looseness at Gun’s fixing nor such
situation that the Gun may touch the coating object.
(7) In case two component paint or any easily depositing paint is used, clean the Gun completely with
solvent right after the coating work, and disassemble the Gun regularly once a three months for
cleaning.

③Other Equipment
(1) Regarding maintenance work for Paint Supplying System, please refer to the separated Operation
Manual for it.
(2) Air regulatory Paint Regulator(Model MRB30) should be cleaned daily, right after its operation, by
removing paint sticking to its Fixing Bracket with solvent.

CAUTION
If any paint sticks to the Fixing Bracket for the Paint Regulator(MRB30), electrostatic may leak
through such stuck paint causing over-current and, then, deficiency of electrostatic coating.

(3) In case two component paint or any easily depositing paint is used, clean the equipment
completely with solvent right after the coating work, and disassemble them regularly for their
cleaning.

7 HOW TO REPLACE PARTS

①Disassembly of Gun Body (Refer to Art.9, “Part List”)

(1) Removal from Gun Bracket
１．First, after confirming that there is no pressure in paint and air lines, remove Shroud (137F-026)
by turning it with hand.
２．Remove two Bolts, M4 x 15, from rear side of the Gun Bracket.
３．Holding Paint Hose, pull out the Gun, where Connecting Cable (2552) will be also pulled out.
Remove the Connecting Cable by turning Cable Fixing Nut, and you can take out the Gun
Body.

CAUTION
Never forget to eliminate the remaining pressure in paint passage. Or else, paint will be pushed
out from paint Hose and sticks to inside of the Gun, through which electrostatic will leak causing
overcurrent and, then, impossibility of electrostatic coating.

(2) Disassembly of Paint Valve

１．Remove two plastic Bolts, M8 x 30, (364-0012) from Gun Head.
２．Pull out Gun Head (137F-001).
３．Remove Cap (137F-012) and pull out Piston by catching its across flats with pincers or others.
４．After pulling out Needle, remove Screw (6008-007). Also, remove Paint Seat (137F-015) at
Gun’s front head using plain driver.
５．After removing Paint Seat, insert a hex. wrench (3mm) into the hole where the Seat was, to push
out Seal Collar (137F-008).
６．As the U Packing (152-0004) inserted in the Seal Collar may be deformed during the Seal
Collar’s removal, replace it with new one.

11
(3) Replacement of Paint Needle
１．Holding across flats (8mm) of Piston with a spanner, loosen and remove Hex. Nut (5.5mm).
２．Pinching the Needle (137F-007), turn and remove Piston (6008-008).
３．After replacing the Needle with new one, assemble those parts taking reverse steps to the
above.

NOTE
Cares should be taken for other parts of Needle not to make them touch
each other at parts holding. Any damage on Packing sliding surface of
Needle may shorten the life of Packing.

Don’t hurt this area.

(4) Cleaning of paint passage in Gun Head

１．Remove Plugs (131E-002, 131F-002) at two points in the Head (137F-001) and remove paint
sticking to inside of it.

NOTE
There are three Plugs at three positions, each of which has its own function.

IN

OUT

Plug Ａ : 131E-002 (short)＝For cleaning of paint passage at paint entrance

Ｂ : 131F-002 (long)＝For paint stop in non-circulation system
Ｃ : 131E-002 (short)＝For water drain from valving air

12
 (5) Replacement of Cascade
１．Take up Cascade (145F-007) to upward from Body (137F-002) and remove three Screws,M2,
(12-10204) from Lead Wire Fixing Terminal at rear end of the Cascade to remove the Wires.
Then, the Cascade can be removed.
２．Lead Wires are combined with Connector (137F-006) as an assembly. To replace the Lead
Wires, always remove the Cascade beforehand.

Terminal on Cascade Lead Wire

ＧＮＤ Green
ＡＣ Yellow
ＲＴＮ Red

②Replacement of Paint Hose

(1) To replace the Hose
１．Remove the Gun Body from its Bracket.
２．Loosen Paint Hose Fixing Pipe at rear side of the Body using spanner, 17mm, and remove the
Hose from Bracket.
(2) To change to paint circulation version
１．Remove Plug (B), put O Ring (130-7004) on another Plug, same as Plug (A) (131E-002), and fix
it to Gun Head.
２．Remove Plug (137F-035) from Bracket and connect the required Paint Hose.

③Replacement of Connecting Cable →Refer to Art. 7 – 1 ”Disassembly of Gun Body”.

④List of Consumable Parts

・ The Spray Gun should be regularly checked referring to the list shown below and, if necessary,
some of its parts should be replaced with new ones.
・ The parts replacement frequency indicated below are for reference only. Lives of Valve parts
fluctuate depending on influences by pigment content in paint and coarseness of paint particles.
In case of the paint containing high abrasive pigment, the lives should be deemed as half.

No. Part No. Name Quantity Replacement Frequency

１６ 1279-022 Valve Seat Ring １ Approx. once a year
７ 137F-007 Needle 1

１５ 137F-015 Paint Seat 1 Approx. once a 2 years

１７ 152-0004 U-packing 1

２２ 101-9014 O-Ring １

３ 145F-007 Cascade １ Approx. once a 5 years

13
 8 TROUBLE SHOOTING

①Relating to paints
Trouble Possible Cause Solution
Spray Pattern ①Loosened Paint Nozzle fixing ①Re-tighten Paint Nozzle
②Damage on Paint Nozzle or seating ②Replace Paint Nozzle or Valve Seat Ring
pulsates surface of Valve Seat Ring
③Air penetration in paint passage ③Check paint level in container and paint suction
seating
①Clogging at Paint Seat ①Remove Paint Seat and clean Seat,
Poor paint output in
Orifice and other paint passages.
spray ②Cholesterol sticking to inside wall of paint ②Remove Plug(A,B) and clean inside.
passage in Gun
③Error in Valve action ③remove Plug(C) from Head, make Gun be on/off to
drain water from inside of Valve Piston.
Replace U Packing or Piston O Ring with new one.
①Paint residue or dust pinched between ①Remove Paint Seat and clean Needle, seating face
Paint doesn’t stop
Paint seat and seating face of Needle and Gun inside.
flow. The dust entered the paints route is
confirmed.
The washing method (time and thinner
dissolubility) is reviewed.
②Error in Valve action ②Remove Plug(C) from Head, make Gun be on/off
to drain water from inside of Valve Piston.
Replace U Packing or Piston O Ring with new one.

①Wear on U Packing in Valve and Needle ①Replace U Packing, Needle and Piston O Ring
Paint leaks from rear
with new ones. Clean all contaminated parts with
end of Bracket solvent and dry them by air blow.

②Relating to electrostatic effect

Trouble Possible cause Solution
①Spray Gun comes too close to grounded ①Check and adjust spray distance.
Error in electrostatic
article Adjust Conveyer and hangers to prevent object’s
effect *1) swinging.
In case of Robot, check if Gun goes too close to
the object and adjust by teaching to Robot.
②Too high humidity in Booth. ②Lower voltage.
③Water penetration into air passage. ③Drain water from air pipings and air passage in the
Gun.
④Dirtiness on Gun Body. ④Remove paint sticking to Shroud and Gun
Body(overall surface and Paint Hose inserting
hole) with solvent and dry by air blow.
⑤Too low paint resistance making current ⑤Adjust to adequate paint resistance 2) or change
flow to grounded paint passage. the paint passage to insulation system *3).
⑥Deposition of metal flakes in paint making ⑥Clean paint passage with solvent. *4).
current flow to grounded paint passage. Change the washing method.
（Thinner dissolubility, flux and washing time）
⑦Failed Cable connection or Cable cut off. ⑦Replace Cable Connector or Cable.
⑧Trouble in Cascade or Controller ⑧Replace Cascade or Controller.

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 NOTE
*
1）As to the indication of electrostatic errors, refer to Operation Manual for Electrostatic
Controller.
*
2）Adequate paint resistance value differs depending on the specifications of paint supplying
system.
*
3）Generally, insulation system for paint passage is necessary when paint resistance value is
10MΩ-cm or less(by Asahi Electrostatic Tester).
*
4）Deposition degree of flakes in metallic paint differs by paint type, but, generally, it is
recommended to clean completely paint passage right after the painting work.

③Items to be checked

Before After
Checking item Weekly Remarks
Operation Operation

Tightness of Gun fixing ○

Valve action and seating ○

Dirtiness on Air Cap, bend of Electrode and deformation of

○ ○
Paint Nozzle

Paint output rate ○

Check also humidity and

Ampere at electrostatic charging ○
paint resistance.

Dirtiness on Shroud ○

Paint sticking to Air Cap ○

Damage on Connecting Cable and looseness at Connectors ○

Damage on Air Tube and Paint Hose, and looseness at their

○
Connectors

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 9
ＥＡＢ９０
BREAKDOWN DRAWINGS AND PART LIST

１３７Ｆ

ROBO GUNⅡ ＥＡＢ９０

No. Part No. Part Name Q’ty Remark No. Part No. Part Name Q’ty Remark
１ 137F-001 Head 1set ２２ 101-9014 O-ring １ P14
２ 137F-002 Body 1set ２３ 130-7004 O-ring ４ S4
３ 145F-007 Cascade １ ２４ 130-7010 O-ring ２ S10
４ 1285-042 Spring １ ２５ 137F-025 Packing １
５ 137F-005 Bracket 1set ２６ 137F-026 Shroud １
６ 137F-006 Connector 1set ２７ 03-70520 Bolt ２ M5X20L
７ 137F-007 Needle １ ２８ 364-0012 Bolt ２ M8X35L
８ 137F-008 Seat collar １ ２９ 15-70300 Hex. nut １
９ 6008-007 Screw １ ３０ 137F-030 Joint １ Valve air
１０ 6008-008 Piston １ ３１ 376-0802 Quick joint ２ Atom. air
１１ 0721-020 Spring １ ３２ 137F-032 Plug １
１２ 137F-012 Cap １ ３３ 12-10204 Screw ３
１３ 131E-002 Plug ２ ３４ 137F-034 Gasket １
１４ 131F-002 Plug １ Return ３５ 130-9032 O-ring １ S32
137F-015 φ1.0 ３６ 102-9065 O-ring １ G65
１５ Paint seat １set
137F-055 φ2.0 (OP) ３７ 137F-037 Name plate 1
１６ 1279-022 Valve seat ring １ ３８ 2552 Connection cable １
１７ 152-0004 U-packing ２ ３９ 3591-026 Hose cover 1
１９ 101-7004 O-ring １ P4 ４０ 356A Tool 1set
２０ 101-7007 O-ring ４ P7 ４２ 364-0019 Screw 1
２１ 101-9005 O-ring １ P5

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10 SERVICE RECORD

It is recommended as helpful for good maintenance and long use of the equipment to fill records of parts
replacement, disassembly and assembly, occurrence of trouble, repair, etc. all given to the equipment in the
columns on this sheet

Equipment ROBO GUNⅡ〈ＥＡＢ９０〉 Purchased on:

Date Part serviced Result Result By

S D A

S D A

S D A

S D A

S D A
NOTE: Due to continuous improvements and modifications, the configurations and specifications of the
equipment specified herein are subject to change without prior notice.

11 SCOPE OF WARRANTY

Asahi Sunac Corporation shall guarantee its products against any defect in design, manufacture or
indication to the original purchaser for the period of 12(twelve) months after the date of purchase, in
the manner as described below.

●In the event any defect in design, manufacture or indication is found on any part of the product,
please return it to us with freight prepaid. If it is confirmed by us, after our investigation, that the
manufacturer is responsible for such defect, the said product shall be repaired or replaced with new
one at free of charge and returned to you with freight prepaid, together with refunding the freight
paid by you.

●In case it is found that the defect has been caused by natural wear, corrosion, carelessness,
accident, Act of God, incorrect installation, rough handling, incorrect operation, operating method
not following to the operation manual or modification not approved by the manufacturer, the
charges for its repair and transportation shall not covered by this warranty.

●This warranty shall be also not applied for any defect or trouble occurred on the product combined
with any hoses, guns or other parts of other made not approved by the manufacturer, and the cost
for its repair, replacement and transportation shall be charged to you, for which such costs shall be
quoted by us with indicating service conditions.

●The warranty conditions for the parts and accessories for the product bought and used by us shall
be subject to the warranty terms and conditions established by the manufacturers of such parts or
accessories.

●Asahi Sunac’s responsibility for warranty shall be deemed as completed by free repair or
replacement of the defective parts.

●Asahi Sunac shall be not responsible for any loss caused by incorrect use of the product or others
beyond of our control.

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●When a transfer of title of this equipment takes place, please see to it that this Operation and
Maintenance Manual is handed over to the new owner.
●This equipment is manufactured in compliance with the Laws and Regulations of Japan. Therefore, use
of this equipment is limited to Japan only. In the rare eventuality of this equipment being used outside
Japan, compliance with the safety standards of the relevant countries is of course mandatory.

14th Edition: October 31, 2011

Leading Manufacturer of Coating FA Systems

ASAHI SUNAC CORPORATION
Head office & Factory: 5050 Asahimae-cho, Owariasahi, Aichi 488-8688 Japan TEL 81-561-52-0717 FAX 81-561-54-8847
e-mail: ctrd01@sunac.co.jp

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