Ransburg 19372 User manual

SERVICE MANUAL
AH-95-02.4AH-95-02.4
AH-95-02.4AH-95-02.4
AH-95-02.4
(Replaces AH-95-02.3)
MODEL: 19372MODEL: 19372
MODEL: 19372MODEL: 19372
MODEL: 19372
IMPORIMPOR
IMPORIMPOR
IMPORTT
TT
TANTANT
ANTANT
ANT: Before using this equipment,: Before using this equipment,
: Before using this equipment,: Before using this equipment,
: Before using this equipment,
carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,
carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,
carefully read SAFETY PRECAUTIONS,
starting on page 1, and all instructions instarting on page 1, and all instructions in
starting on page 1, and all instructions instarting on page 1, and all instructions in
starting on page 1, and all instructions in
this manual. Keep this Service Manual forthis manual. Keep this Service Manual for
this manual. Keep this Service Manual forthis manual. Keep this Service Manual for
this manual. Keep this Service Manual for
future reference.future reference.
future reference.future reference.
future reference.
NO. 2 PROCESS HANDGUNNO. 2 PROCESS HANDGUN
NO. 2 PROCESS HANDGUNNO. 2 PROCESS HANDGUN
NO. 2 PROCESS HANDGUN
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.)Service Manual Price: $30.00 (U.S.)

NOTE:NOTE:
NOTE:NOTE:
NOTE: This manual has been changed from revision AH-95-02.3AH-95-02.3
AH-95-02.3AH-95-02.3
AH-95-02.3 to revision AH-95-02.4 AH-95-02.4
AH-95-02.4 AH-95-02.4
AH-95-02.4.
Reasons for this change are noted under Manual Change Summary inside the back
cover of this manual.

AH-95-02.4
SAFETY:SAFETY:
SAFETY:SAFETY:
SAFETY:
SAFETY PRECAUTIONS.........................................................
HAZARDS / SAFEGUARDS.....................................................
PAGEPAGE
PAGEPAGE
PAGE
INTRODUCTION:INTRODUCTION:
INTRODUCTION:INTRODUCTION:
INTRODUCTION:
CONTENTSCONTENTS
CONTENTSCONTENTS
CONTENTS
THE PROCESS.........................................................................
SPECIFICATIONS.....................................................................
GUN FEATURES......................................................................
OPERATION:OPERATION:
OPERATION:OPERATION:OPERATION:
PROCEDURES.........................................................................
GUN ELECTRICAL OUTPUT...................................................
MAINTENANCE:MAINTENANCE:
MAINTENANCE:MAINTENANCE:
MAINTENANCE:
EFFECTS OF SOLVENTS.......................................................
SCHEDULES.............................................................................
TEST PROCEDURES..............................................................
REPAIR PROCEDURES..........................................................
CABLE / MOTOR ASSEMBLY.................................................
HANDLE ASSEMBLY...............................................................
BARREL ASSEMBLY................................................................
TROUBLESHOOTING GUIDE.................................................
1-51-5
1-51-51-5
6-76-7
6-76-7
6-7
14-1914-19
14-1914-1914-19
20-4320-43
20-4320-4320-43
1
2
6
7
7
14
18
20
22
22
24
27
29
35
40
PARTS IDENTIFICATION:PARTS IDENTIFICATION:
PARTS IDENTIFICATION:PARTS IDENTIFICATION:
PARTS IDENTIFICATION:
CABLE / CABLE MOTOR ASSEMBLY.....................................
BARREL ASSEMBLY................................................................
HANDLE ASSEMBLY................................................................
FLUID SUPPLY HARDWARE...................................................
ACCESSORIES.........................................................................
NO. 2 PROCESS HAND GUN PARTS LIST...........................
RECOMMENDED SPARE PARTS...........................................
44-5144-51
44-5144-5144-51
44
45
46
47
48
49
51
WARRANTY POLICIES:WARRANTY POLICIES:
WARRANTY POLICIES:WARRANTY POLICIES:
WARRANTY POLICIES: 5252
5252
52
LIMITED WARRANTY............................................................... 52
APPENDIX:APPENDIX:
APPENDIX:APPENDIX:APPENDIX:
PAINT AND SOLVENT SPECIFICATIONS.............................
VISCOSITY CONVERSION CHART........................................
VOLUMETRIC CONTENT OF HOSE OR TUBE.....................
53-5653-56
53-5653-56
53-56
53
54
56
INSTALLATION:INSTALLATION:
INSTALLATION:INSTALLATION:
INSTALLATION:
PRE-INSTALLATION REQUIREMENTS.................................
SAFEGUARDS..........................................................................
EQUIPMENT INSTALLATION..................................................
8-138-13
8-138-13
8-13
8
8
8

AH-95-02.4

AH-95-02.4
SAFETY PRECAUTIONSSAFETY PRECAUTIONS
SAFETY PRECAUTIONSSAFETY PRECAUTIONS
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg coating system, read and understand
all of the technical and safety literature for your
Ransburg products. This manual contains in-
formation that is important for you to know and
understand. This information relates to USER
SAFETY and PREVENTING EQUIPMENT
PROBLEMS. To help you recognize this infor-
mation, we use the following symbols. Please
pay particular attention to these sections.
A WARNING! states information to alert youA WARNING! states information to alert you
A WARNING! states information to alert youA WARNING! states information to alert you
A WARNING! states information to alert you
to a situation that might cause serious injuryto a situation that might cause serious injury
to a situation that might cause serious injuryto a situation that might cause serious injuryto a situation that might cause serious injury
if instructions are not followed.if instructions are not followed.
if instructions are not followed.if instructions are not followed.
if instructions are not followed.
A CAUTION! states information that tellsA CAUTION! states information that tells
A CAUTION! states information that tellsA CAUTION! states information that tells
A CAUTION! states information that tells
how to prevent damage to equipment orhow to prevent damage to equipment or
how to prevent damage to equipment orhow to prevent damage to equipment or
how to prevent damage to equipment or
how to avoid a situation that might causehow to avoid a situation that might cause
how to avoid a situation that might causehow to avoid a situation that might cause
how to avoid a situation that might cause
minor injury.minor injury.
minor injury.minor injury.
minor injury.
A NOTE is information relevant to 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-
A NOTE is information relevant to the proce-
dure in progress.dure in progress.
dure in progress.dure in progress.
dure in progress.
While this manual lists standard specifications
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 draw-
ings and appropriate Ransburg equipment
manuals to reconcile such differences.
Careful study and continued use of this manual
will provide a better understanding of the equip-
ment and process, resulting in more efficient op-
eration, 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 represen-
tative or Ransburg.
SAFETYSAFETY
SAFETYSAFETY
SAFETY
The user MUSTMUST
MUSTMUST
MUST read and be familiar
with the Safety Section in this manual and
the Ransburg safety literature therein
identified.
This manual MUSTMUST
MUSTMUST
MUST be read and thor-
oughly understood by ALLALL ALLALLALL personnel who
operate, clean or maintain this equipment!
Special care should be taken to ensure that
the WARNINGSWARNINGS
WARNINGSWARNINGS
WARNINGS and safety requirements
for operating and servicing the equipment
are followed. The user should be aware of
and adhere to ALLALL ALLALLALL local building and fire
codes and ordinances as well as NFPA 33NFPA 33
NFPA 33NFPA 33
NFPA 33
SAFETY STANDARD, SAFETY STANDARD,
SAFETY STANDARD, SAFETY STANDARD, SAFETY STANDARD, prior to installing,
operating, and/or servicing this equipment.
The hazards shown on the following
page may occur during the normal use of
this equipment. Please read the hazard
chart beginning on page 2.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
W A R N I N GW A R N I N G
W A R N I N GW A R N I N GW A R N I N G
!!
!!
!
11
11
1

AH-95-02.4
22
22
2
ARE AARE A
ARE AARE AA REA
Tells where
hazards may occur.
HAZARDHAZARD
HAZARDHAZARDHAZARD
Tells what the hazard is.
SAFEGUARDSSAFEGUARDS
SAFEGUARDSSAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
Spray AreaSpray Area
Spray AreaSpray AreaSpray Area Electrostatic Arcing Never operate the spray gun without properly
grounding the following.
A. Operators
Operators must be grounded. Rubber soled
insulating shoes should not be worn. Grounding
leg straps may be used.
Operators must maintain contact with the
handle of the gun. If work gloves are used, the
palm section 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
OPERATOR GROUNDING.
B. Parts being sprayed. Resistance between the
part and a grounded conveyor must not exceed
1 megohm.
C. Every metal and conductive object in the spray
area. This includes the booth, parts hangers,
fire extinguishers, conductive flooring, etc.
Grounded conductive flooring must be provided in
the spray area.
Turn off voltage at the power supply before flushing
out, cleaning, or removing any parts from the gun.
Provide proper protection for waterborne supply
systems.
Never install a spray gun into a fluid system using
an isolated solvent supply.
Always discharge Waterborne system capacitance
prior to servicing.
Do not touch gun electrode while gun is energized.

AH-95-02.4 33
33
3
ARE AARE A
ARE AARE AA REA
Tells where
hazards may occur.
HAZARDHAZARD
HAZARDHAZARDHAZARD
Tells what the hazard is.
SAFEGUARDSSAFEGUARDS
SAFEGUARDSSAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
Spray AreaSpray Area
Spray AreaSpray AreaSpray Area
Improper operation or mainte-
nance may create a hazard.
Personnel must be properly
trained in the use of this equip-
ment.
Personnel must be given training in accordance
with the requirements of NFPA 33.
Instructions and safety precautions must be read and
understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation
maintenance, and housekeeping. OSHA references
are Sections 1910.94 and 1910.107. Also refer to
NFPA 33 and your insurance company requirements.
General UseGeneral Use
General UseGeneral UseGeneral Use
andand
andand
and
MaintenanceMaintenance
MaintenanceMaintenanceMaintenance
Fire Hazard
Improper or inadequate operation
and maintenance procedures will
cause a fire hazard.
Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any
safety interlocks are disabled
during operation. Frequent
power supply shutdown indicates
a problem in the system requir-
ing 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, flushing, or maintenance.
When using solvents for cleaning:
Those used for equipment flushing should have flash
points equal to or higher than those of the coating
material.
Those used for general cleaning must have flash
points above 100oF (37.8oC).
Spray booth ventilation must be kept at the rates
required by NFPA 33, OSHA and local codes. In
addition, ventilation must be maintained during
cleaning operations using flammable or combustible
solvents.
Electrostatic arcing must be prevented.
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 modifications may cause fire 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.
Never use equipment intended for use in waterborne
installations to spray solvent based materials.

AH-95-02.4
ARE AARE A
ARE AARE AA REA
Tells where
hazards may occur.
HAZARDHAZARD
HAZARDHAZARDHAZARD
Tells what the hazard is.
SAFEGUARDSSAFEGUARDS
SAFEGUARDSSAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
Explosion Hazard/Explosion Hazard/
Explosion Hazard/Explosion Hazard/Explosion Hazard/
IncompatibleIncompatible
IncompatibleIncompatible
Incompatible
MaterialsMaterials
MaterialsMaterialsMaterials
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.
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, flushing, 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 material supplier.
Any other type of solvent may be used with aluminum
equipment.
Use of hand tools may cause
cumulative trauma disorders
(CTD's). CTD's or musculoskel-
etal disorders, involve damage to
the hands, wrists, elbows, shoul-
ders, neck and back. Carpal
tunnel syndrome and tendinitis
(such as tennis elbow or rotator
cuff syndrome) are examples of
CTD's.
CTD's when using hand tools,
tend to affect the upper extremi-
ties. Factors which may in-
crease the risk of developing a
CTD include:
1. High frequency of the activity.
2. Excessive force, such as
gripping, pinching or pressing
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 temperatures.
Risk is reduced by avoiding or lessening the listed
hazards.
CTD's can also be caused by such activities as
sewing, golf, tennis and bowling, to name a few.
Pain, tingling, or numbness in the shoulder, fore-
arm, wrists, hands, or fingers, especially during the
night, may be early symptoms of a CTD. Do not
ignore them. Should you experience any such
symptoms, see a physician immediately. Other
early symptoms may include vague discomfort in
the hand, loss of manual dexterity, and non-spe-
cific pain in the arm. Ignoring early symptoms and
continued repetitive use of the arm, wrist and hand
can lead to serious disability.
General Use andGeneral Use and
General Use andGeneral Use and
General Use and
MaintenanceMaintenance
MaintenanceMaintenance
Maintenance
44
444

AH-95-02.4
ARE AARE A
ARE AARE AA REA
Tells where
hazards may occur.
HAZARDHAZARD
HAZARDHAZARDHAZARD
Tells what the hazard is.
SAFEGUARDSSAFEGUARDS
SAFEGUARDSSAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
ElectricalElectrical
ElectricalElectricalElectrical
EquipmentEquipment
EquipmentEquipment
Equipment
High voltage equipment is utilized.
Arcing in areas of flammable or
combustible materials may occur.
Personnel are exposed to high
voltage during operation and
maintenance.
Protection against inadvertent
arcing that may cause a fire or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shutdown
indicates a problem in the system
which requires correction.
An electrical arc can ignite coat-
ing materials and cause a fire or
explosion.
The power supply, optional remove control cabinet,
and all other electrical equipment must be located
outside Class I or II, Division 1 and 2 hazardous
areas (refer to NFPA No. 33).
Turn the power supply OFF before working on the
equipment.
Test only in areas free of flammable 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.
Toxic SubstancesToxic Substances
Toxic SubstancesToxic Substances
Toxic Substances Certain material may be harmful
if inhaled, or if there is contact
with the skin.
Follow the requirements of the Material 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.
Personnel SafetyPersonnel Safety
Personnel SafetyPersonnel Safety
Personnel Safety Skin puncturing by sharp
electrode.
Take precautions to see that flesh is not punctured
by sharp electrode.
55
55
5

AH-95-02.4
INTRODUCTIONINTRODUCTION
INTRODUCTIONINTRODUCTION
INTRODUCTION
66
66
6
THE PROCESSTHE PROCESS
THE PROCESSTHE PROCESS
THE PROCESS
This is a method of applying electrostatically at-
omized coating material. The No. 2 Process
Handgun System applies a high voltage, DC
negative charge to the applicator bell, creating
an electrostatic field between the bell and the
target object. The target is electrically grounded
through its support (which may be stationary or
moving) or through an electrical connection to a
known earth ground.
A regulated pressure fluid system delivers
coating material to the bell when the gun is
triggered. There, the fluid travels across the
face of the rotating bell and is charged. The
fluid is atomized at the edge of the bell forming a
fine mist, which under the influence of the
electrostatic field is attracted to and deposited
on the target object. The forces between the
charged particles and the grounded target are
sufficient to turn most normal overspray around
and deposit it on the rear surface of the target.
Therefore, most of the spray is deposited and
overspray is controlled. This process makes
the No. 2 Process Handgun one of the most
efficient electrostatic spray products on the
market.
The No. 2 Process Handgun applies a DC
negative charge to the coating materials at the
point of atomization. The electrostatic charge
allows a more efficient, uniform application of
coating material to the front, edges, sides, and
back of products, making it highly suitable for
applying coatings to a variety of surface con-
figurations; large targets, tubular products, small
parts, fencing, etc. Because it is a grounded
fluid system, it is highly suitable for applying a
wide range of solvent reduced coatings such as
enamels, epoxies, etc.
One of the many features of the No. 2 Process
Handgun is that the electrical discharge, which
is available from the resistive charging brush, is
limited to the optimum combination of safety and
efficiency.
The No. 2 Process Handgun System includes
the Hand Gun, the High Voltage Power Supply,
the High Voltage Cable, and Fluid Hose.

AH-95-02.4
SPECIFICASPECIFICA
SPECIFICASPECIFICA
SPECIFICATIONSTIONS
TIONSTIONS
TIONS
MechanicalMechanical
MechanicalMechanical
Mechanical
Fluid Input Pressure:Fluid Input Pressure:
Fluid Input Pressure:Fluid Input Pressure:Fluid Input Pressure: 50 psi (3.5 bar)
(maximum)
Fluid Delivery Rate:Fluid Delivery Rate:
Fluid Delivery Rate:Fluid Delivery Rate:Fluid Delivery Rate: (maximum)
2-3/4" Bell Size:2-3/4" Bell Size:
2-3/4" Bell Size:2-3/4" Bell Size:
2-3/4" Bell Size: 75 cc/minute
(2.5 oz/minute)
4" Bell:4" Bell:
4" Bell:4" Bell:4" Bell: 120 cc/minute
(4 oz/minute)
6" Bell:6" Bell:
6" Bell:6" Bell:6" Bell: 180 cc/minute
(6 oz/minute)
Application Rate:Application Rate:
Application Rate:Application Rate:Application Rate: (maximum)
2-3/4" Bell:2-3/4" Bell:
2-3/4" Bell:2-3/4" Bell:
2-3/4" Bell: 5-7 ft2/minute
(.46-.65 m2/minute)
4" Bell:4" Bell:
4" Bell:4" Bell:4" Bell: 10-12 ft2/minute
(.93-1.11 m2/minute)
6" Bell:6" Bell:
6" Bell:6" Bell:6" Bell: 15-18 ft2/minute
(1.39-1.67 m2/minute)
Environmental / PhysicalEnvironmental / Physical
Environmental / PhysicalEnvironmental / Physical
Environmental / Physical
Length:Length:
Length:Length:
Length: 20 inches (508 cm)
Weight:Weight:
Weight:Weight:Weight: 56 ounces (1588 g)
ElectricalElectrical
ElectricalElectrical
Electrical
Input Voltage:Input Voltage:
Input Voltage:Input Voltage:
Input Voltage: 110 or 220 VAC
50/60 Hertz
Output Voltage:Output Voltage:
Output Voltage:Output Voltage:
Output Voltage: 100 kV DC (negative)
Current:Current:
Current:Current:
Current: 30-50 microamperes
(operating)
SCI:SCI:
SCI:SCI:
SCI: 100 microamperes
(maximum)
Paint Resistance:*Paint Resistance:*
Paint Resistance:*Paint Resistance:*
Paint Resistance:* .1 to 1 M
**
***(Ransburg Meter)
77
77
7
Note:Note:
Note:Note:
Note: Conversion 29.5 cc (ml) = 1 oz
GUN NOMENCLAGUN NOMENCLA
GUN NOMENCLAGUN NOMENCLA
GUN NOMENCLATURETURE
TURETURE
TURE
Figure 1: Gun Features / Model 19372Figure 1: Gun Features / Model 19372
Figure 1: Gun Features / Model 19372Figure 1: Gun Features / Model 19372
Figure 1: Gun Features / Model 19372

AH-95-02.4
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
DO NOTDO NOT
DO NOTDO NOT
DO NOT use the power supply
ground wire to ground the target objects.
C A U T I O NC A U T I O N
C A U T I O NC A U T I O N
C A U T I O N
!!
!!
!
88
88
8
PRE-INSTPRE-INST
PRE-INSTPRE-INST
PRE-INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
REQUIREMENTSREQUIREMENTS
REQUIREMENTSREQUIREMENTS
REQUIREMENTS
1. Provide approved electrical wiring to the
power supply. See NFPA Bulletin No.
33, OSHA regulations, and your local
codes.
2. Make sure the operating location has ad-
equate grounding facilities, such as elec-
trical conduit, steel building columns,
metal water pipes, or other earth
grounded objects.
3. Furnish a paint pressure pot with air
regulator (or other accepted pressure
system). The regulator MUST have a
reliable control, with a recommended
gauge range of 0-30 psig (0-2.1 kg/cm2).
4. Provide proper ventilation. (See "Safety"
section of this manual.)
5. Ensure that the target object to be
coated and all surrounding objects are
grounded to a known, positive ground by
a separate ground wire attachment.
SAFEGUARDSSAFEGUARDS
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
When operating this equipment in the vicinity of
computers, word processors, and/or other elec-
tronic equipment, special care MUST be taken
to ensure that damage does not occur from
electrical energy discharges. (See Ransburg
safety literature for further information regarding
application.)
The following guidelines can be used:
 It is highly recommended, whenever possible,
that ALL electronic components or equipment
be removed from the spray area. This in-
cludes computer software such as tapes,
disks, diskettes, etc., located inside and/or
around the spray area.
 If the static shielding of a unit is NOT
KNOWN, all electronic components (such as
terminals, screens, and cables) should be
completely wrapped in aluminum foil and
grounded to a true earth ground.
 When painting electrical control panels or con-
soles, wrap all push-buttons, switches,
meters, or pilot lights with aluminum foil and
ground to the panel or other earth ground.
EQUIPMENTEQUIPMENT
EQUIPMENTEQUIPMENT
EQUIPMENT
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
NEVERNEVER
NEVERNEVER
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.
Efficiency of the applicator will also be
reduced and damage or failure of the
applicator's components may occur.
WRAPPING THESE COMPONENTSWRAPPING THESE COMPONENTS
WRAPPING THESE COMPONENTSWRAPPING THESE COMPONENTSWRAPPING THESE COMPONENTS
IN PLASTIC WILL VOID WARRANTY.IN PLASTIC WILL VOID WARRANTY.
IN PLASTIC WILL VOID WARRANTY.IN PLASTIC WILL VOID WARRANTY.
IN PLASTIC WILL VOID WARRANTY.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
Before attempting to install the equipment, en-
sure that all the necessary components are
available (see "Parts Identification" section of
this manual). In addition, read all the technical
and safety literature that is provided. If the lit-
erature is not available, contact your local
Ransburg Distributor where the equipment was
purchased.

AH-95-02.4 99
99
9
The power source wiring and the power
supply connections to it MUST meet all local
fire and electrical code standards and
comply with all appropriate OSHA regula-
tions. See NFPA No. 33, NFPA-70 (NEC)
Article 516.5, and the OSHA Act, Section
1910.107.
All power supplies MUST be grounded
before any other connections are made or
functions performed. DO NOT use the
power supply ground wire to ground the
target objects (use LSME4000-00 clamp
assembly)!
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
Power SupplyPower Supply
Power SupplyPower Supply
Power Supply
-REFER TO FIGURE 2-REFER TO FIGURE 2
-REFER TO FIGURE 2-REFER TO FIGURE 2
-REFER TO FIGURE 2
See the appropriate power supply service
manual for the proper electrical connections.
1. The high voltage power supply MUST be
located at least 20 feet (6.1 m) from the
spraying operation. If a spray booth is
used, the power supply may be located
5 feet from the nearest opening and out-
side the booth (see NFPA No. 33).
2. If a line cord is used instead of a perma-
nent conduit connection, ensure the
ground lead is present on the plug. En-
sure that the electrical outlet is properly
wired by using the circuit tester (20868-
00). Attach the green ground wire to a
proven, true earth ground (i.e., water
pipe or electrical conduit).
3. After the power supply is grounded to a
suitable earth ground, the handgun high
voltage cable and fluid hoses may be
connected. The power supply may then
be connected to the power source.
4. Install the adapter (item 72) to the fluid
source. Attach one end of the fluid hose
(item 71) to the adapter.
Bell Cleaning CanBell Cleaning Can
Bell Cleaning CanBell Cleaning Can
Bell Cleaning Can
The bell cleaning safety can MUST be
electrically grounded! The bell MUST be
removed from the gun to clean!
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
The bell cleaning safety can is provided to
safely contain any appropriate cleaning solvent.
At no time should the barrel of the handgun be
inserted into the bell cleaning can.
Figure 2: Equipment Installation DiagramFigure 2: Equipment Installation Diagram
Figure 2: Equipment Installation DiagramFigure 2: Equipment Installation Diagram
Figure 2: Equipment Installation Diagram
GUN HOLDER
74

AH-95-02.4
1010
1010
10
Gun HolderGun Holder
Gun HolderGun Holder
Gun Holder
-REFER TO FIGURE 2-REFER TO FIGURE 2
-REFER TO FIGURE 2-REFER TO FIGURE 2-REFER TO FIGURE 2
The gun holder (item 74) is bar designed to be
bolted to a vertical surface (i.e., workbench,
etc.). The hollow gun handle fits over the bar for
holding the handgun when the gun is not being
used.
After attaching the gun holder to the fixture, the
bar should be adjusted so that the handgun sits
at approximately a 15o angle downward. This
prevents paint and/or solvent from running back
onto the gun.
No. 2 Process HandgunNo. 2 Process Handgun
No. 2 Process HandgunNo. 2 Process Handgun
No. 2 Process Handgun
-REFER TO FIGURES 2, 3, 4, & 12-REFER TO FIGURES 2, 3, 4, & 12
-REFER TO FIGURES 2, 3, 4, & 12-REFER TO FIGURES 2, 3, 4, & 12
-REFER TO FIGURES 2, 3, 4, & 12
Once the power supply has been properly in-
stalled and wired, the No. 2 handgun can be in-
stalled.
1. Insert 1/2 to 1 ounce of dielectric oil
(item 84) into the high voltage cable re-
ceptacle inside the power supply.
2. Install and secure the high voltage cable
to the power supply.
3. Install hose fitting on the fluid hose as
shown in Figure 3.
Ensure oil is directed ONLY into white
high voltage tube.
NOTENOTE
NOTENOTENOTE
Ransburg supplies a standard 25 foot
hose. Optional hose lengths of 36, 50, 75,
and 100 feet are available. To meet vari-
ous length requirements, the hose fitting on
one end has not been attached.
NOTENOTE
NOTENOTE
NOTE
Figure 3: Line Fitting InstallationFigure 3: Line Fitting Installation
Figure 3: Line Fitting InstallationFigure 3: Line Fitting Installation
Figure 3: Line Fitting Installation
4. Connect filter assembly (item 80) to
hose connector assembly (item 65).
Connect fluid line assembly (item 71) to
the filter assembly. Connect the oppo-
site end of fluid line assembly to the
paint source. An adapter (item 72) is
supplied for the fluid line assembly if it
is required. This adapter connects to a
3/8"-16 NPS male fitting.
Determine the hose length that is needed
and cut the hose. Attach the other fitting as
follows:
1. Lubricate all fittings with dielectric grease
(item 83).
2. Screw ferrule counterclockwise onto hose
until it bottoms, then back it off 1/8 of an
inch.
3. Install nut over union stem and start the
stem into the hose.
4. Using the 3/16-inch Allen wrench, screw
the union stem into the hose until it bot-
toms against the ferrule.

AH-95-02.4 1111
1111
11
The bell and feed tube MUSTMUST
MUSTMUST
MUST be
matched to ensure proper fluid feed into
the bell cavity. The following chart will as-
sist in selecting the proper bell and feed
tube combination:
NOTENOTE
NOTENOTENOTE
@ 2 oclock
@ 4-5 oclock
@ 4-5 oclock
6335-00
3700-00
4076-00
2-3/4
4
6
Bell Size Feed Tube # Position of TubeBell Size Feed Tube # Position of Tube
Bell Size Feed Tube # Position of TubeBell Size Feed Tube # Position of Tube
Bell Size Feed Tube # Position of Tube
Replacing the plastic set screw with one
of conductive material (metal) will cause a
hazardous condition to exist, capable of
producing an electrical discharge possible of
sparking a fire.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
5. Attach the proper feed tube (item 12) to
the front of the handgun. Position the
feed tube at about 1 o'clock. See Fig-
ures 1 and 2.
6. Attach the bell assembly (item 66) to the
front of the handgun. Hold the shaft of
the handgun and rotate the bell onto the
shaft until the bell is completely seated.
Tighten the set screw (item 70) at the
bell hub.
7. Position the feed tube (item 12) in the
bell cavity at approximately the 4 to 5
oclock position. The feed tube should
NOTNOT
NOTNOTNOT rub on the bell. Adjust the feed
tube if necessary, by rotating it or sliding
it forward or backward in the barrel.
8. Adjust the high voltage contact brush
(item 41) so that the raised button of
plastic on the brush is rubbing on the
outside back coated surface of the bell
(see Figure 4).
NOTES:NOTES:
NOTES:NOTES:
NOTES:

AH-95-02.4
1212
1212
12
No. 2 Handgun BrushNo. 2 Handgun Brush
No. 2 Handgun BrushNo. 2 Handgun Brush
No. 2 Handgun Brush
Positioning and WearPositioning and Wear
Positioning and WearPositioning and Wear
Positioning and Wear
-REFER TO FIGURE 4-REFER TO FIGURE 4
-REFER TO FIGURE 4-REFER TO FIGURE 4
-REFER TO FIGURE 4
When installing the electrical contact brush (P/N
3695-00), it is important that it is properly posi-
tioned to provide LIGHT CONTACTLIGHT CONTACT LIGHT CONTACTLIGHT CONTACTLIGHT CONTACT with the
bell conductive coating. Excessive contact
pressure from the contact brush will wear away
the conductive coating or the brush tip, causing
poor electrical contact. The small plastic pad at
the tip of the brush arm should lightly contact
the black bell coating, not the wirenot the wire not the wirenot the wirenot the wire. The tip of
the brush should not extend past the edge of the
bell cup or into the radius at the edge (see Fig-
ure 4). The brush should normally have a slight
When the radius portion of the plastic
tip is gone, this is equal to one-half of the
brush tip.
NOTENOTE
NOTENOTE
NOTE
curve to the arm. The more pressure applied
the lesser the curve (see Figure 4). The tip of
the brush assembly must be inspected prior to
each use for wear. When one-half (1/2) of the
plastic tip is worn away the brush assembly
should be replaced (see Figure 4).
Figure 4: Feed Tube and Brush PositioningFigure 4: Feed Tube and Brush Positioning
Figure 4: Feed Tube and Brush PositioningFigure 4: Feed Tube and Brush Positioning
Figure 4: Feed Tube and Brush Positioning
BRUSH
CONTACT AREA
CONTACT POSITION
UN-INSTALLED BRUSH SHAPE
1/4" TO 1/2"
FEED TUBE AND BRUSH CONTACT POSITIONING
GOOD TIP WORN TIP

AH-95-02.4 1313
1313
13
When the gun switch is ON, the bell will
be rotating and high voltage will be acti-
vated. Steps MUSTMUST MUSTMUSTMUST be taken to ensure
grounding of personnel and equipment for
safety. Electrical shock may occur if the
equipment is NOTNOT
NOTNOT
NOT grounded.
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!
!
PaintPaint
PaintPaint
Paint
A proper paint mixture is essential to the electro-
static operation. Due to the method of atomiza-
tion, the electrical characteristics and viscosity
levels of the paint are important to ensure
proper application. Paint test equipment such
as the test assembly (76652-03) for testing
paint electrical resistivity, may be purchased
through your Ransburg distributor. See also
"Paint and Solvent Specifications" in the "Ap-
pendix" section of this service manual.
Most paint suppliers may be of assistance in
preadjusting the paint for proper electrostatic
sprayability.
NOTES:NOTES:
NOTES:NOTES:
NOTES:

AH-95-02.4
OPERAOPERA
OPERAOPERA
OPERATIONTION
TIONTION
TION
The quality of atomization can be tested
by shooting a donut test pattern on a
grounded flat surface at approximately a
6-inch target distance. Coarse atomization
may be caused by excessive fluid delivery
(high fluid pressure or wrong bell size) or
improper electrical resistance of the coating
material. Adjust parameters according to
atomization quality and results.
NOTENOTE
NOTENOTE
NOTE
The green indicator shows AC power
into the power supply, and the red pilot
light indicates high voltage power to the
handgun.
NOTENOTE
NOTENOTE
NOTE
It is important, while operating, to keep
the gun positioned toward the grounded
target to avoid paint wrapback onto the
operator or nearby objects.
C A U T I O NC A U T I O N
C A U T I O NC A U T I O NC A U T I O N
!!
!!
!
1414
1414
14
PROCEDURESPROCEDURES
PROCEDURESPROCEDURES
PROCEDURES
Prior to operating the No. 2 Handgun, ensure
that the equipment is installed properly (see "In-
stallation" section of this service manual). Ob-
serve and follow the safety requirements at ALL
times.
1. Inspect the rotating bell assembly (item
66) to ensure that it is clean and is not
chipped. Replace or clean the bell as-
sembly when necessary.
2. Set the paint fluid pressure at 3 to 4 psi
(0.2 to 0.3 kg/cm2). Adjust the pressure
up or down for the desired fluid delivery.
Higher fluid pressure may be needed
with higher viscosity material, longer
hoses, or higher fluid deliveries.
3. Set the switch (item 26) to the off posi-
tion prior to turning the power supply on.
Turn the AC power ON at the power
supply (and at the remote switch in the
booth on permanent installations).
4. Turn the No. 2 gun motor ON at the
switch (item 26) on the rear of the hand-
gun.
5. Hold the No. 2 handgun perpendicular
to, and 4 to 7 inches (13 to 18 cm) from
the part being coated. Trigger the hand-
gun and observe the atomization of the
coating material.
Rotational speed of the bell will be ap-
proximately 600 rpm.
NOTENOTE
NOTENOTE
NOTE
6. Move the No. 2 handgun in a smooth
horizontal or vertical line or in a smooth
circular motion, maintaining a constant
distance between the target and the bell
surface. (See Ransburg manual IL-211,
"No. 2 Handgun Spray Techniques").
For an accurate measurement of paint
delivery with any paint being used, turn the
handgun motor OFF, and remove the bell.
Using a graduated cylinder or beaker and a
stopwatch, trigger the gun and collect the
fluid for one minute. Measure the paint vol-
ume collected to get fluid flow rate per
minute. See maximum "Fluid Delivery
Rate" under "Specifications" in the "Intro-
duction" section of this manual.
NOTENOTE
NOTENOTE
NOTE

AH-95-02.4 1515
1515
15
Operations Near Computers orOperations Near Computers or
Operations Near Computers orOperations Near Computers or
Operations Near Computers or
Other Electronic DevicesOther Electronic Devices
Other Electronic DevicesOther Electronic Devices
Other Electronic Devices
For over 35 years, the No. 2 Process Handgun
has been the most widely used tool by the on-
site painting industry for the refinishing of office
furniture, office panels, lockers, school furniture,
and dozens of other items.
Quite often we are asked about the dangers and
possible damage to computers, phone systems,
word processors, and electronically keyed
security systems when electrostatic painting is
done nearby.
Concerning those types of applications or any
microprocessor base equipment, the following
facts should be noted:
1. The No. 2 Process Handgun is not elec-
tromagnetic. It is electrostatic (much
like the static from carpets or wool and
synthetic clothing), and works at an out-
put of 100 kilovolts at 30-50 microam-
peres current draw. (100 microamperes
maximum short circuit current).
Grounding of all conductive objects
near an electrostatic spray gun is of the
highest importance.
NOTENOTE
NOTENOTE
NOTE
2. Unlike x-rays, electrostatic does not go
"through" objects.
3. Some computers, phone systems, or
word processors are now shielded by
the manufacturer against outside static.
4. If the static shielding of a unit is unknown,
the keyboard, CPU (central processing
unit), monitor, or phone and its cable
preferably should be removed from the
immediate painting area for protection of
the device. If this is not feasible, they
should be completely wrapped in
aluminum foil that is grounded to an earth
ground. This will create a "Faraday cage"
around the computerized device.
5. Electrical sparks of all types create an
R.F. energy (radio frequency) that may
radiate through the air and enter into
electronic circuits. The resulting damage
is unpredictable.
6. Computer software such as tapes, disks,
diskettes, etc., should be removed from
inside of and from the immediately
surrounding area of any enclosures that
are to be painted.
7. Lightning or electrostatic voltage sparking
into an A.C. circuit can create "spikes" or
electromagnetic pulse (EMP) that can
cause unpredictable damage to electronic
hardware.
8. Surge suppressors are available that may
help protect appliances from "spikes" of
current if the suppressor is in the A.C. line
supplying the appliance.
9. When painting any type of electrical
control panel or console it is generally not
known if all push-button, switches,
meters, or pilot lights are properly
grounded. In view of this, it is desirable to
cover all of these items with aluminum foil
which is grounded to the panel or another
earth ground.
10. All on-site painting companies should
have adequate liability insurance to
protect them in the event of any real or
perceived damage as a result of their
operations.
In view of the above unknown and possible
uncontrolled conditions, ITW does not
recommend the electrostatic spray painting of
computer cabinets, consoles, or painting in
close proximity to these devices.

AH-95-02.4
1616
161616
ShutdownShutdown
ShutdownShutdown
Shutdown
These steps are to be followed during a shut-
down for short periods such as breaks, lunch,
downtime, etc.
1. Release the trigger. Allow two to five
seconds for the paint to quit flowing off
the bell then turn OFF OFF OFF OFF OFF the gun motor.
Turn the power supply OFFOFF
OFFOFF
OFF (at the
booth wall switch for permanent installa-
tions or at the master switch on the
power supply for mobile operations).
2. Place the feed tube in the one oclock
position. Loosen the set screw on the
bell hub. Then hold the shaft collar with
one hand and turn the bell on the shaft
with the other hand as you pull it forward
off the shaft.
3. Clean the bell with a soft brush (nonme-
tallic) or cloth and a suitable solvent.
The bell MUSTMUST
MUSTMUST
MUST be cleaned if the spray-
ing is to be interrupted for more than a
few minutes.
BEFOREBEFORE
BEFOREBEFOREBEFORE attempting any cleaning or
color change procedures, the high voltage
and the AC power to the power supply
MUSTMUST
MUSTMUST
MUST be turned OFF!OFF!
OFF!OFF!
OFF!
W A R N I N GW A R N I N G
W A R N I N GW A R N I N G
W A R N I N G
!!
!!!
The bell MUSTMUST
MUSTMUST
MUST be cleaned if the gun
will not be operated again within a few
minutes. If two component catalyzed
paint is used, frequent bell cleaning and
flushing may be required. (See "Color
Change" in the "Operation" section.)
C A U T I O NC A U T I O N
C A U T I O NC A U T I O N
C A U T I O N
!!
!!
!
4. Dry the bell and reinstall it on the shaft.
Rest the feed tube and contact brush.
End of ShiftEnd of Shift
End of ShiftEnd of Shift
End of Shift
These steps are to be followed during a shut-
down for extended periods of time exceeding
one hour. Time may vary according to the ap-
plications and material being used.
1. Release the trigger and allow the bell to
rotate until it is clear of paint. Then turn
the gun motor OFF.
2. Turn the power supply OFF.
3. Remove and clean the bell (follow the
steps under "Shutdown" in the "Opera-
tion" section).
4. Place the gun (bell angled down) on the
gun support rack to prevent solvent and
paint from getting into the unit.
5. Flush the paint hose, gun, and feed tube
with solvent.
DO NOTDO NOT
DO NOTDO NOT
DO NOT soak the bell in solvent as
this may deteriorate its black conductive
coating. See "Solvent Effects on #2
Handgun Bell / Brush Wear" (SI-03-03)
and "Paint and Solvent Specifications" in
the "Appendix" section of this manual.
C A U T I O NC A U T I O N
C A U T I O NC A U T I O N
C A U T I O N
!!
!!!
Check the equipment frequently after the initial
installation and establish flushing schedules
based on the observed requirements. Normally,
the system should be flushed at least once
each day or per an eight-hour shift. (See the
paint supplier for recommendations regarding
catalyzed paints).
The frequency of flushing depends
upon:
 Paint type
 Paint viscosity
 Whether the system is circulating
or non-circulating
 Whether the paint system is
heated or not
 Hours of use, etc.
NOTENOTE
NOTENOTENOTE