Ransburg DR-1 User manual

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS, starting
on page 4, and all instructions in this manual. Keep this Service Manual for future reference.
Model: 74151
DR-1 Fluid Regulator
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EN
SERVICE MANUAL

NOTE: This manual has been changed from revision LN-9223-00.11 to revision
LN-9233-00-R12. Reasons for this change are noted under “Manual
Change Summary” inside the back cover of this manual.
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MANUAL CHANGES
EN

CONTENTS
SAFETY: 4-8
Safety Precautions .................................................................................................................................................... 4
Hazards / Safegaurds ................................................................................................................................................ 5
INTRODUCTION: 9-10
Features .................................................................................................................................................................... 9
 Specications ............................................................................................................................................................ 9
DR-1 Flow vs. Signal Pressure ................................................................................................................................ 10
OPERATION: 11
Operation ..................................................................................................................................................................11
MAINTENANCE: 12-17
Tools Required ........................................................................................................................................................ 12
Preliminary Procedures ........................................................................................................................................... 12
Disassembly Procedures ......................................................................................................................................... 12
Regulator Cross-Sectional View .............................................................................................................................. 13
Assembly Procedures ............................................................................................................................................. 14
Test Procedures ...................................................................................................................................................... 15
Preventive Maintenance .......................................................................................................................................... 15
Troubleshooting Guide ............................................................................................................................................. 16
PARTS IDENTIFICATION: 18-20
Regulator Cross-Sectional View .............................................................................................................................. 18
DR-1 Fluid Regulator Parts List................................................................................................................................ 19
Recommended Spare Parts .................................................................................................................................... 20
Service Kits ............................................................................................................................................................. 20
MANUAL CHANGE SUMMARY: 21
Manual Changes ..................................................................................................................................................... 21
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CONTENTS
EN

CAUTION
!
WARNING
!
NOTE
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any Ransburg
electrostatic coating system , read and understand all of the
technical and safety literature for your Ransburg products.
This manual contains information that is important for you
to know and understand. This information relates to USER
SAFETY and PREVENTING EQUIPMENT PROBLEMS.
To help you recognize this information, we use the following
symbols. Please pay particular attention to these sections.
A WARNING! states information to alert you to
a situation that might cause serious injury if
instructions are not followed.
A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.
A NOTE is information relevant to the procedure
in progress.
Whilethismanuallistsstandardspecicationsandservice
procedures, some minor deviations may be found between
this literature and your equipment. Differences in local codes
and plant requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this manual with
your system installation drawings and appropriate Ransburg
equipment manuals to reconcile such differences.
Careful study and continued use of this manual will provide a
better understanding of the equipment and process, resulting
inmoreefcientoperation,longertrouble-freeserviceand
faster, easier troubleshooting. If you do not have the manuals
and safety literature for your Ransburg system, contact your
local Ransburg representative or Ransburg.
WARNING
!
WARNING
!
The user MUST read and be familiar with the
Safety Section in this manual and the Ransburg
safetyliteraturethereinidentied.
This equipment is intended to be used by
trained personnel ONLY.
This manual MUST be read and thoroughly un-
derstood by ALL personnel who operate, clean or
maintain this equipment! Special care should be tak-
en to ensure that the WARNINGS and safety require-
ments for operating and servicing the equipment are
followed. The user should be aware of and adhere
to ALLlocalbuildingandrecodesandordinances
as well as NFPA-33 AND EN 50176 SAFETY STAN-
DARDS, LATEST EDITION, or applicable country
safety standards, prior to installing, operating, and/or
servicing this equipment.
The hazards shown on the following pages may
occur during the normal use of this equipment. Please
read the hazard chart beginning on page 2.
SAFETY
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area Fire Hazard
Improper or inadequate
operation and maintenance
procedureswillcauseare
hazard.
Protection against inadvertent
arcing that is capable of
causingreorexplosionislost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
Fireextinguishingequipmentmustbepresentinthe
spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be
turnedoffpriortocleaning,ushingormaintenance.
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, country, and local
codes. In addition, ventilation must be maintained
duringcleaningoperationsusingammableor
combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between the
parts being coated and the applicator. A distance of
1 inch for every 10KV of output voltage is required
at all times.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but only
as instructed.
Non-factory replacement parts or unauthorized
equipmentmodicationsmaycausereorinjury.
If used, the key switch bypass is intended for use
only during setup operations. Production should
never be done with safety interlocks disabled.
The paint process and equipment should be set up
and operated in accordance with NFPA-33, NEC,
OSHA, local, country, and European Health and
Safety Norms.
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Improper or inadequate
operation and maintenance
procedures will cause a
rehazard.
Protection against inadvertent
arcing that is capable of
causingreorexplosionislost
if any safety interlocks are
disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system
requiring correction.
Electrostatic arcing must be prevented. Safe sparking
distance must be maintained between the parts being
coated and the applicator. A distance of 1 inch for
every 10KV of output voltage is required at all times.
Unlessspecicallyapprovedforuseinhazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Testonlyinareasfreeofammableorcombustible
materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding
section of the equipment manual. Protection against
inadvertentarcingthatiscapableofcausingre
orexplosionislostifthecurrentoverloadsensitivity
is not properly set. Frequent power supply
shutdown indicates a problem in the system which
requires correction.
Always turn the control panel power off prior to
ushing,cleaning,orworkingonspraysystem
equipment.
Beforeturninghighvoltageon,makesurenoobjects
are within the safe sparking distance.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance with
NFPA-33, EN 50176.
Havereextinguishingequipmentreadilyavailable
and tested periodically.
Improper operation or
maintenance may create
a hazard.
Personnel must be properly
trained in the use of this
equipment.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
Instructions and safety precautions must be read
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codesgoverningventilation,reprotection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms and your
insurance company requirements.
General Use and
Maintenance
Spray Area Explosion Hazard
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
There is a high voltage device
that can induce an electrical
chargeonungroundedobjects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materialsandcauseare
orexplosion.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on
conveyors or hangers that are properly grounded.
The resistance between the part and earth ground
mustnotexceed1megohm.(RefertoNFPA-33.)
Operators must be grounded. Rubber soled
insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungroundedmetalobjects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator
via conductive gloves or gloves with the palm section
cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
Allelectricallyconductiveobjectsinthesprayarea,
withtheexceptionofthoseobjectsrequiredbythe
process to be at high voltage, must be grounded.
Groundedconductiveooringmustbeprovidedin
the spray area.
Alwaysturnoffthepowersupplypriortoushing,
cleaning, or working on spray system equipment.
Unlessspecicallyapprovedforuseinhazardous
locations, all electrical equipment must be located
outside Class I or II, Division 1 or 2 hazardous
areas, in accordance with NFPA-33.
Avoidinstallinganapplicatorintoauidsystem
where the solvent supply is ungrounded.
Do not touch the applicator electrode while it is
energized.
Electrical Discharge
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may
occur. Personnel are exposed
to high voltage during operation
and maintenance.
Protection against inadvertent
arcingthatmaycauseareor
explosionislostifsafetycircuits
are disabled during operation.
Frequent power supply shut-
down indicates a problem in
the system which requires
correction.
An electrical arc can ignite
coating materials and cause a
reorexplosion.
Unless specically approved for use in hazardous
locations, the power supply, control cabinet, and all
other electrical equipment must be located outside
Class I or II, Division 1 and 2 hazardous areas in
accordance with NFPA-33 and EN 50176.
Turn the power supply OFF before working on the
equipment.
Testonlyinareasfreeofammableorcombustible
material.
Testing may require high voltage to be on, but only
as instructed.
Production should never be done with the safety
circuits disabled.
Before turning the high voltage on, make sure no
objectsarewithinthesparkingdistance.
Electrical Discharge
Electrical
Equipment
Certain materials may be
harmful if inhaled, or if there is
contact with the skin.
Follow the requirements of the Safety Data Sheet
supplied by coating material manufacturer.
Adequateexhaustmustbeprovidedtokeeptheair
freeofaccumulationsoftoxicmaterials.
Use a mask or respirator whenever there is a chance
of inhaling sprayed materials. The mask must be
compatible with the material being sprayed and its
concentration. Equipment must be as prescribed
by an industrial hygienist or safety expert, and be
NIOSH approved.
Chemical HazardToxic Substances
Sprayapplicatorsrequirethataluminuminletttings
be replaced with stainless steel.
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators,
triggering valves, etc. Halogenated hydrocarbon
solvents must never be used with aluminum
equipment during spraying, ushing, or cleaning.
Read the label or data sheet for the material you
intend to spray. If in doubt as to whether or not a
coating or cleaning material is compatible, contact
your coating supplier. Any other type of solvent may
be used with aluminum equipment.
Halogenated hydrocarbon
solventsforexample:
methylene chloride and
1,1,1,-Trichloroethane are not
chemically compatible with the
aluminum that might be used
in many system components.
The chemical reaction
caused by these solvents
reacting with aluminum can
become violent and lead to an
equipmentexplosion.
Explosion Hazard —
Incompatible Materials
Spray Area
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SAFETY
EN

INTRODUCTION
FEATURES
• Twoindependentlycontrolledowpressureranges.
• Highowrangeportforhigheruiddeliveries.
• Low ow range for more precise control over lower
uiddeliveries.
SPECIFICATIONS
Environmental/Physical
Mechanical
• Interchangeablelowowratios(1:1,1:2,1:3,1:4,1:6,
1:8, 1:10) for precise control.
• Stainless steel and coated wetted parts for decreased
color change time.
Height: 1-7/8-inch (48mm)
Height W/Fittings: 2-1/8-inch (54mm)
Diameter: 2-3/4-inch (70mm)
Diameter W/Fittings: 3-3/8-inch (86mm)
Air Pressures: VariablebyControl(ManualorAutomatic)100psi(7barmax.)
Fluid Input: 300psi(20.7barmax.)(10psiminimumaboveoutputpressure)
Fluid Output: Variable by Ratio
Pneumatic / Fluid Connections
Air Pilot: #10-32 Thread (Low & High)
Fluid In: 1/4-inch NPSM Thread
Fluid Out: 1/8-inch NPSM Thread
3/16-inch OD Tubing, use 70589-04 Fitting
1/4-inch OD Tubing, use 70589-05 Fitting
3/8-inch OD Tubing, use 70589-10 Fitting
6mm OD Tubing, use 70589-06 Fitting
8mm OD Tubing, use 70589-11 Fitting
3/8-inch NPSM Hose Connection, use 70589-12 Fitting
Volume of Paint Held Within Regulator: 5 cc
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INTRODUCTION
EN

DR-1 FLOW VS SIGNAL PRESSURE
900
800
700
600
500
400
300
0
9 12 15 21 26 32 37 42 48 54 59 65 70 75 81
SIGNAL PRESSURE (PSI)
FLOW (CC/MIN)
DR-1 Flow vs. Signal Pressure
1400
1200
1000
800
600
400
200
0
FLOW (CC/MIN)
DR-1 Flow vs. Signal Pressure
200
100
9 12 15 21 26 32 37 42 48 54 59 65 70 75 81
SIGNAL PRESSURE (PSI)
Viscosity=40 sec.
Zahn #2
15ft 1/4 I.D. tubing
.093orce
Viscosity=25 sec.
Zahn #2
15ft 1/4 I.D. tubing
.093orce
1:1
1:2
1:3
1:4
1:6
1:8
1:10
HIGH FLOW
HIGH FLOW 1:2
1:1
1:3
1:4
1:6
1:8
1:10
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INTRODUCTION
EN

OPERATION
WARNING
!
The DR-1 Regulator is designed to provide remote control
uidregulationforautomaticcoatingapplications.
Theregulatorfeaturestwoindependentlycontrollableow
pressurerangesfromtheuidoutputport.Thehighow
rangeportaccom-modateshigheruiddeliveriesandmin-
imalcolorchangetimes.Thelowerowrangesprovide
preciseuiddeliverycontrol.Therearesevenlowerrange
models available (1:1, 1:2, 1:3, 1:4, 1:6, 1:8, and 1:10)
whichcanbeselectedbasedontherequireduidowrate.
Separate pilot signals modulate each of the regu-lator’s two
diaphragms to control the amount of paint being delivered
from the regulator to the spray applicator.
Because of the regulator’s dual range capabilities, it provides
theuserexibilityforselectingeitherthehighowrangeor
thelowowrange.Differentcoatingmaterialviscosities
and quick color change requirements may necessitate the
use of both ranges. If color change time is not a factor or
if material viscosity remains relatively constant, either port
may be used depending on ow rate requirements. All
regulators, regardless of ratio designation, have the high
owport.
Thelowow(i.e.1:2,1:4,etc.)portprovidesalower,more
preciseowresponsecurve.Fluidoutput,asaresult,is
less likely to be affected by pilot signal errors. An increase
in the ratio (i.e. from 1:2 to 1:4) provides a lower slope in the
ow/airsignalpressurecurve,butamorepreciseresponse
curve. This same increase in ratio however, will reduce
ow capacity and should be considered when selecting
the proper regulator ratio.
The following factors must then be considered when se-
lectingtheregulatorratiorequiredforproperuidcontrol:
• Fluid tubing inside diameter (ID) and length
• Fluid feed tube inside diameter (ID) and length
• Fluid viscosity
• Fluid input pressures
Preliminary testing will determine which regulator ratio
should be used. If conditions change after installation
whichrequireadifferentlowowratio,thisregulatorcan
beeasilyalteredbyreplacingtheexistingratiospacerring
and upper retainer with the desired ratio (ratio designation
is etched on the side of the spacer ring).
NEVER wrap the applicator, associated valves
and tubing, and supporting hardware in plastic to
keep it clean. A surface charge may build up on the
plastic surface and discharge to the nearest grounded
object.Efciencyoftheapplicatorwillalsobereduced
and damage or failure of the applicator components
may occur. WRAPPING THESE COMPONENTS IN
PLASTIC WILL VOID WARRANTY.
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OPERATION
EN

MAINTENANCE
CAUTION
!
NOTE
CAUTION
!
PRELIMINARY PROCEDURES
Prior to removing the regulator for service or repair, perform
the following:
1. If possible, ush the regulator with suitable cleaning
solvent.
2. Turn the uid and air "OFF" to the regulator and
disconnecttheairanduidlinesfromtheregulator.
3. Remove the regulator for service.
DISASSEMBLY PROCEDURES
(Refer to Figure 1)
TOOLS REQUIRED
 • 3/8",7/16",7/8",and15/16"Open-EndWrenches
 • 5/32"AllenHeadWrench
 • AdjustableWrench
• Screwdriver
• Repair Kit, 73913-00 or 73913-01
1. Remove Item 4 (8 screws) holding the regulator assembly
togetherwiththe5/32"Allenwrench.
Unless replacing Item 1 (cap) and/or Item 2
(spacer ring), it is NOT necessary to remove Item 18
(airtting)andItem15(gasket).
Item 11 (regulating needle and seat) is a
matching set with matching serial numbers. Care
must be taken to not use needles and seats with
non-matchingserialnumbersasuidleakagemay
occur. If either component needs to be replaced, a
new matched set must be used.
When separating parts it may be necessary to
use a small screwdriver. Care should be taken to
NOT damage the components. Damage of these
parts may cause leakage.
2
. Remove Item 1 (cap), Item 9 (upper diaphragm), Item
2 (spacer ring), and Item 3 (lower housing assembly).
This will leave the diaphragm assembly Item 5 (upper
diaphragm retainer), Item 14 (center diaphragm), Item 7
(center diaphragm retainer), Item 17 (bleed spacer), Item
8 (lower diaphragm), Item 10 (o-ring), and Item 6 (lower
diaphragm retainer) held together by Item 16 (screw).
3. With a screwdriver, remove Item 16 (screw) from the
diaphragm assembly.
4. Separate Item 6 (lower diaphragm retainer), Item 10
(o-ring), Item 8 (lower diaphragm), Item 17 (bleed
spacer), Item 14 (center diaphragm), and Item 5 (upper
diaphragm retainer).
5. With  the 7/8" and the 15/16" open-end wrenches,
remove Item 13 (retaining plug), Item 12 (spring,) and
Item 11 (regulating needle) from Item 3 (lower housing).
6. Remove Item 11 (regulating seat) and Item 10 (o-ring)
from the lower housing assembly.
7. Clean all metal parts with suitable cleaning solvent.
DO NOT use solvent on the diaphragms or o-rings.
Care MUST be taken while cleaning the coated
parts of the regulator to prevent scratching.
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MAINTENANCE
EN

Figure 1: Regulator Cross-Sectional View
14
2
18
8
7
610
1
16 9
54
15
17
3
10
10
11
13
12
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MAINTENANCE
EN

ASSEMBLY PROCEDURES
(Refer to Figure 1)
1. Inspect Item 11 (regulating needle and seat) for
damage. If either of these items are damaged or the
mating surfaces are scratched, both items should be
replaced as a matching set.
2. Discard the following items and replace them with the
new item from the 73913-00 or 73913-01 repair kit:
Item 16 Screw
Item 10 O-Ring
Item 9 Upper Diaphragm
Item 14 Center Diaphragm
Item 8 Lower Diaphragm
3. Place Item 10 (o-ring) in the slot on Item 6 (lower
diaphragm retainer).
4. Place Item 8 (lower diaphragm) on Item 6 (lower
diaphragm retainer) with the side of the diaphragm
contacting the retainers (o-ring side).
5. Stack the following parts on Item 8 (lower diaphragm),
in the following order:
Item 7 (Center Diaphragm Retainer)
Item 18 (Bleed Spacer)
Item 14 (Center Diaphragm)
Item 5 (Upper Diaphragm Retainer)
Item 16 (Screw)
6. Ensure that clearance holes in Items 8 and 14
(diaphragms) and Item 17 (bleed spacer) are aligned
properly and tighten Item 16 (screw). Use adhesive 222
on screw threads. Set the diaphragm assembly aside.
7. Place Item 3 (lower housing) on table with bottom
threadedopeningfacing"UP".
8. Insert Item 10 (o-ring) onto Item 11 (regulating seat) and
then insert the assembly into Item 3 (lower housing).
Thebeveledsideoftheregulatingseatmustbe"UP".
9. Place Item 11 (regulating needle) into Item 3 (lower
housing) with the ball end against Item 11 (regulating
seat).
10. Place Item 10 (o-ring) on Item 13 (retaining plug).
11. Place Item 12 (spring) into Item 3 (lower housing)
over Item 11 (regulating needle) and thread Item 13
(retaining plug) into Item 3 (lower housing). Tighten
Item 13 (retaining plug) to 25-30 lbs•ft, ensuring that
Item 11 (regulating needle) and Item 12 (spring) remain
in the center of Item 3 (lower housing).
12. Place Item 3 (lower housing) on table with bowl facing
"UP" and place diaphragm assembly (from step 4)
into bowl of Item 3 (lower housing), with pin of Item 6
(lowerdiaphragmretainer)facing"DOWN".Rotatethe
diaphragm assembly so that the slot on Item 6 (lower
retainer) is 180oto the outlet port of Item 3 (lower
housing)forcleanerushingoftheregulatorassembly.
NOTE
CAUTION
!
CAUTION
!
DO NOT scratch the coating.
Apply a small amount of non-silicone lubricant to
Item 10 (o-ring) prior to assembly.
Verify regulator seat and needle have matching
serial numbers.
13. Place Item 2 (spacer ring) on the top of Item 14 (center
diaphragm)withlargestopeningfacing"DOWN".Rotate
Item 2 (spacer ring), without rotating the diaphragm
assembly, so that the air pilot port of Item 2 (spacer
ring) is 45oto the outlet port of Item 3 (lower housing)
and all the clearance holes are aligned (see Figure 1).
14. Place Item 9 (upper diaphragm) on Item 2 (spacer ring)
and align holes.
15. Place Item 1 (cap) on Item 9 (upper diaphragm). Align
holes and insert Item 4 (8 screws).
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MAINTENANCE
EN

TEST PROCEDURES
(Refer to Figure 1)
After repair is complete, test the regulator in the following
manner:
1. Setairanduidregulatorstozeroandattachairand
uidlinestotheregulator.
2. Gradually increase air pressure to the regulator to 80
psi, visually checking for leaks. Tighten Item 4 (screws)
if leakage occurs.
3. Setairregulatortozero.Graduallyincreaseuidpressure
to 80 psi, visually checking for leakage. Clean or replace
Item 11 (needle and seat) if leakage at outlet port.
PREVENTIVE MAINTENANCE
1. Rebuild with 73913, Repair Kit, and 74160-00, needle
andseat,at6monthsminimum,12monthsmaximum.
2. Re-torque eight (8) screws at the following intervals:
• 2 days after rebuild
• Immediately before installation
• 6 month intervals
4. Gradually increase air pressure on either of the air
linesandvisuallyobserveagradualincreaseinuid
ow.Ifregulatordoesnotperformsatisfactorily,inspect
components for damage and replace where required.
16. Tighten opposing screws alternately to 10 lbs•in, ensur-
ing uniform sealing of the diaphragms. Then follow by
tightening each screw in a circle pattern to 20 lbs•in.
17. IfItem15(airttings)wereremovedfromeitherItem
2 (spacer ring) or Item 1 (cap), screw them along with
Item 18 (gasket) back onto these items.
CAUTION
!
DO NOTovertightentheairttings.Overtightening
thettingsmaycausethestemofthettingtosnapoff.
NOTE
If water or solvent is used for testing, it is normal
forminorleakagetooccurattheuidoutputport,due
tothelowviscositiesoftheseuids.
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General Problem Possible Cause Solution
TROUBLESHOOTING GUIDE
(Continued On Next Page)
No Fluid Flow
Fluid Will Not
Shut Off
Paint Leakage
Air Leakage
Low Fluid Flow
Pluggeduidinlet
Item 11 (regulating needle and seat) stuck
No pilot air
Ruptured Item 9 (upper diaphragm)
Ruptured Item 14 (center diaphragm)
Dirt in Item 11 (regulating needle/seat)
Pilot air not shut off
Broken Item 12 (spring)
Item 4 (screws) loose
Ruptured Item 8 (lower diaphragm)
Item 13 (retaining plug) loose
Looseuidtting
Item 10 (o-ring) pinched
Looseairtting
Item 4 (screws) loose
Ruptured Item 9 (upper diaphragm)
Ruptured Item 14 (center diaphragm)
Incorrect regulator ratio
Fluid supply pressure to low.
Air pilot to low.
Flush clean.
Remove and clean or replace.
Check air pilot signal.
Rebuild regulator.
Rebuild regulator.
Remove and clean or replace. (Must be replaced
asaset,see"Maintenance"section.)
Check signal air supply.
Replace item 12 (spring).
Tightenper"AssemblyProcedure"inthe
"Maintenance"section.
Rebuild regulator.
Tighten, torque to 25-30 lbs•ft
(see"Maintenance"section).
Tighten.
Replace Item 10 (o-ring).
Tighten.
Tighten.
Rebuild regulator.
Rebuild regulator.
Referto"Operations"sectionforcorrect 
sizing information.
Increaseuidsupplypressure.(Donotexceed
100psig(see"Specications"inthe
"Introduction"section).
Check air pilot signal.
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MAINTENANCE
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General Problem Possible Cause Solution
TROUBLESHOOTING GUIDE (Cont.)
Inconsistent Fluid
Flow
High Fluid Flow
Item 8 (lower diaphragm) stretched from
excessiveairpilotsignal
Ruptured Item 9 (upper diaphragm)
Ruptured Item 14 (center diaphragm)
Inconsistent air pilot
Inconsistentuidsupplypressure
Incorrect regulator ratio
Fluid supply pressure too high
Rebuild regulator.
Rebuild regulator.
Rebuild regulator.
Check pilot air supply.
Checkuidsupply.
Referto"Operations"sectionforcorrect  
sizing information.
Loweruidsupplypressure.
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PARTS IDENTIFICATION
Figure 2: Regulator Cross-Sectional View
14
2
18
8
7
610
1
16 9
54
15
17
3
10
10
11
13
12
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PARTS IDENTIFICATION
EN

DR-1 Regulator Assembly Select Options Below
Ratio 1:1 74151-11
Ratio 1:2 74151-01
Ratio 1:3 74151-06
Ratio 1:4 74151-02
Ratio 1:6 74151-03
Ratio 1:8 74151-04
Ratio 1:10 74151-05
1 Cap 74152-00 1
2 Spacer Ring, For: Select Options Below 1
Ratio 1:1 74153-11
Ratio 1:2 74153-01
Ratio 1:3 74153-06
Ratio 1:4 74153-02
Ratio 1:6 74153-03
Ratio 1:8 74153-04
Ratio 1:10 74153-05
3 Lower Housing 74154 1
4 Screw, Socket Head Cap 8212-28F 8
5 Upper Diaphragm Retainer, For: Select Options Below 1
Ratio 1:1 74155-00
Ratio 1:2 75374-01
Ratio 1:3 75374-06
Ratio 1:4 75374-02
Ratio 1:6 75374-03
Ratio 1:8 74155-00
Ratio 1:10 74155-01
6 Diaphragm Retainer, Lower 74156-00 1
7 Diaphragm Retainer, Center 74231-00 1
8* Diaphragm, Lower 74273-00 1
9* Diaphragm, Upper 74157-03 1
10* O-Ring Select Options Below 3
 .489"IDx.070"c/s,SolventResistant 7554-11
 .489"IDx.070"c/s,SolventProof 79001-08(Optional)
11 Needle & Seat, Regulating 74160-00 1
12 Spring 74161-00 1
13 Retaining Plug 74162-00 1
14* Diaphragm, Center 74157-04 1
15 Fitting, Air 7892-12 2
Item # Part #
Description Qty
* Parts contained in Repair Kit
DR-1 FLUID REGULATOR - PARTS LIST (Figure’s 1 & 2)
(Continued On Next Page)
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PARTS IDENTIFICATION
EN

74156-00 Diaphragm Retainer, Lower 1
74160-00 Needle and Seat, Regulating 1
74161-00 Spring 1
73913-00 Repair Kit, W/Solvent Resistant O-Rings
73913-01 Repair Kit, W/Solvent Proof O-Rings
Item # Part #
Description Qty
DR-1 FLUID REGULATOR - PARTS LIST (Figure’s 1 & 2) (Cont.)
16* Screw, Pan Head 74183-20C 1
17 Gasket 72135-00 2
18 Bleed Spacer 74232-00 1
20 Paint Fitting (not included), For: Select Options Below
 3/16"ODTubing 70589-04
 1/4"ODTubing 70589-05
 3/8"ODTubing 70589-10
6mm OD Tubing 70589-06
8mm OD Tubing 70589-11
 3/8"NPSMHoseConnection 70589-12
* Parts contained in Repair Kit
Part # Description Qty
RECOMMENDED SPARE PARTS
Part # Description
SERVICE KITS
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PARTS IDENTIFICATION
EN