Operation and Maintenance Manual

Automatic Electrostatic Air Spray Gun

Robogun III

EAB400

This manual contains important information on warnings and cautions. Read the
manual thoroughly before starting to operate the equipment, and follow the
instructions. Always keep the manual handy until such time as the equipment is no
longer being used. If your manual is lost or worn badly, do not hesitate to contact
our agency which is closest to you, or the Asahi Sunac Corporation, directly, and
ask us to send you a new one.
Introduction
Thank you for buying our product, Automatic Electrostatic Air Spray Gun Sungun III
(EAB400).

Before you use the equipment, carefully read this manual and get to know how to use it
safely, efficiently and effectively. Especially, fully understand the operating conditions
described in the specifications, as well as warnings, cautions, notes and “do’s and don’ts”
in the manual. Following these instructions, get the most out of the equipment for many
years to come.

This product is designed to be used together with the static electricity controller (BPS260).
Be sure to read through the Instruction Manual for the electrostatic controller.

The painting equipment in this manual is for professional use only, calling for a qualified
person to operate. Use of the equipment should, therefore, be limited to those who have
acquired operation and application skills through an authorized training course. Should you
have any questions about the manual, please get in touch with us at the addresses, phone
and fax numbers as shown on the back of this manual.

In order for us to give you an answer that’s relevant to your particular needs, do not forget
to give us the “model” and “serial number” of your equipment at that time.
Contents

1 For Your Safety ······································································································1

2 Equipment Overview ······························································································· 5
2.1 Names and Roles of Parts ···················································································5
2.1.1 Names and roles of main unit parts ··································································5
2.2 Names of Connections on Back Plate·····································································6
2.3 Items on Rating Plate ·························································································6
2.4 Component of Gun (Main Body) ············································································7
2.5 Related Accessory Parts (Optionally Available) ························································7
2.5.1 Air cap (Model: HN Series) ·············································································7
2.5.2 Electrostatic controller (BPS290 Series) ····························································8
2.5.3 Power transmission cable ··············································································8
2.5.4 Paint hose ··································································································9
2.5.5 Connection of each component ····································································· 10
3 Specifications ······································································································ 11
3.1 Outline Drawing ······························································································· 11
3.2 Product Specifications ······················································································ 11
4 Precautions before Operation ·················································································· 12
5 Preparation for Coating ·························································································· 13
5.1 Paint ············································································································· 13
5.2 Adjustment of Air ····························································································· 15
5.3 Spraying Distance ···························································································· 16
5.4 Travel Speed ·································································································· 16
5.5 Paint Spray Cut ······························································································· 16
5.6 Voltage Applied ······························································································· 16
5.7 System Operation Procedures ············································································ 16
5.8 Precautions to Be Taken at Stoppage and End of Spraying Operations ······················· 17
6 Maintenance and Inspection···················································································· 20
6.1 Procedure to Finish Operation ············································································ 20
6.1.1 When the operation is resumed within 24 hours ················································ 20
6.1.2 When the operation is not resumed within 24 hours ··········································· 23
6.2 Maintenance of Other Equipment ········································································ 25
6.3 Periodical Inspections ······················································································· 25
6.4 Consumable Part ····························································································· 27

1
Contents

7 Paint Problems and Solutions ·················································································· 28

8 Troubleshooting ···································································································· 30
9 How to Replace Parts ···························································································· 32
9.1 Disassembly of Gun Body ·················································································· 32
9.2 Replacement of Paint Hose ················································································ 33
9.3 Replacement of Connecting cable ······································································· 34
9.4 Installing Orifice ······························································································· 39
10 Exploded Diagram and Names of Parts······································································ 35
10.1 EAB400········································································································ 35
10.2 Replacement Parts ························································································· 37
11 Maintenance Log ·································································································· 38
12 Warranty ············································································································· 39

1
 1 For Your Safety

Please read and follow all the technical and safety instructions in this manual.
Failure to do so may result in personal injury and/or property damage.

While all the safety precautions in the manual are very important, you should not consider them to be as cure-all.
They are nothing but minimum requirements. You may need some other types of safety precautions: in fact,
you may come across with other types of hazards not shown in the manual down the road. And, of course,
there are regulatory and voluntary safety requirements set forth by the governments and businesses.

So, shown below and in the pages that follow are the basic minimum safety precautions in connection with
use of our product.

●Safety precautions are classified into three categories based on the severity of hazards involved.
Alerts a hazardous situation which may result in personal injury, along with
WARNING hazard avoidance measures.
Alerts a hazardous situation which may result in equipment damage or breakage, along with
CAUTION hazard avoidance measures.

NOTICE Indicates important methods and practical information.

* Safety precautions classified into the CAUTION category could cause personal injury if not properly
followed. To ensure safety and prevent equipment failure, always observe the safety precautions and
follow the hazard avoidance measures.

1
 WARNING
<<Applicability of this product>>

This manual is designed specifically for the

automatic electrostatic air spray gun <EAB400>.

This product is an automatic spray gun. It is installed on a coating booth equipped with exhaust
equipment and is used to paint using electrostatic air spray.

Use this product in a spray booth with the capabilities stipulated by the relevant laws and regulations
or in a place under equivalent ventilation conditions.

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. Do not use this product as pointing it to human beings and animals. It may cause serious injury
such as irritation and/or poisoning symptom due to hazardous substances.

2. If a pace maker is used within the use scope of this product, the pace maker may malfunction or
stop due to the effect of high voltage.

3. When you enter a place (coating booth, etc.) where this product is used, be sure to wear
appropriate protective gears (working clothes, electrostatic shoes, protective glasses, gas mask,
gloves, and other gears stipulated in JIS T8103).
Failure to do so, static electricity may be charged in a human body, resulting in a spark discharge.
In addition, a hazardous substance may be affixed to your eyes and/or skin, causing irritation
and/or poisoning symptom and you may cut your body by protrusions, etc.

4. Properly ventilate the place all the time using a ventilator where this product is used so that
volatilized organic solvent, etc. will not remain in it.

5. If you handle this product when you are in bad condition, correct risk determination may be
delayed, resulting in a serious accident.

6. When you find any failures such as abnormal noise, abnormal oscillation, and high voltage
leakage, etc. while you are using this product, immediately stop the operation. If you keep
operating this product as a failure is found, it may cause fire and/or breakage of the product.

7. Do not use halogenated hydrocarbon solvent. It may chemically react with aluminum alloy in the
components of this product, resulting in an explosion.

8. Do not bring equipment and/or tools, etc. such as a match and lighter which discharge sparks into
the place where this product is used. Such equipment and tools may ignite inflammables,
resulting in an explosion and/or fire.

2
 WARNING

9. If this product is used outside the scope of the equipment specifications, it may cause fire and/or
breakage of the product. Be sure to use this product within the scope of the equipment
specifications.

10. Check the assembling state of each equipment before operating this product so that operation
can be done without breakage and/or loss of the parts.

11. Have the safe operation training for the relevant coating equipment before you start handling the
coating equipment. Those who have not had the safe operation training are not allowed to handle
the coating equipment.

12. Make sure to ground the static electricity controller. Grounding of the static electricity controller is
the basic safe operation. The coating equipment is also grounded from the static electricity
controller, and therefore be sure to ground it.

13. Make sure that the work piece subject to coating is constantly grounded. When objects are metal,
the grounding resistance should be under 1 kΩ; when objects are plastic, the grounding
resistance should be under 1 MΩ. (The measurement voltage must be 500 V or higher.)
The work piece subject to coating is normally connected to ground through the conveyer and/or
hanger. However, if any paint adheres to its contact area with the hanger, a ground failure occurs
and the work piece is charged, resulting in a fire due to a spark. Make sure to regularly remove
paint adhered to the hanger.

14. Ground all the electric conductors and paint containers in the coating booth using grounding wires.
In the coating booth, the ambient atmosphere around the coating equipment is ionized by high
voltage, and therefore the electric conductors and thinner containers which are not grounded may
be charged by atmospheric convection and spark when a grounded body comes close to such
conductors and containers. Do not place unnecessary paint cans and tools, etc. in the coating
booth. Ground the paint containers if they are stored near the entrance of the coating room even if
it is outside the room.

15. Operate the coating equipment with bare hands. The grips of the coating equipment are grounded
through the electric static controller. If you operate the equipment as wearing gloves which are not
specified in JIS T8103, electricity is charged in your body, and when you come close to or contact
other grounded body, an electrical shock or fire may occur. When you use gloves which are not
specified in JIS T8103, open a large hole in the palm section of the gloves so that your palms can
contact the grips.

16. Those who are involved with electrostatic coating, cleaning of the coating equipment, and
maintenance operation, and those who work around such operations must wear electrostatic
shoes so that a human body will not be charged with electricity. Always check that paint is not
affixed on the soles of the electrostatic shoes.

17. The floor for coating operation must have an antistatic structure. An antistatic structure resistant to
1 MΩ or less must be applied to the entire working floor in the case of a closed coating room and
to the area surrounded by 1.5 m at the both sides and 2.5 m at the front of the booth opening in
the case of an open coating room, and the area must be kept clean.

18. Make sure to stop supplying paint and air and turn off the electrostatic controller air when cleaning
nozzles. If high voltage is applied upon cleaning of the nozzles, it may cause fire. Be sure to turn
off the electrostatic controller when the operation is suspended or completed. Do not touch the
tips of the nozzles while high voltage is being applied.

3
 WARNING
19. NEVER use any metal brushes to clean the nozzles. The nozzles are important parts of the
coating equipment.
If the nozzles are damaged by a metal brush, uniform atomization becomes unavailable. Use a
bamboo brush, etc. to clean the nozzles. Since the electrode pins are sharp and easily pierce
fingers, etc., be careful when handling them.

20. Do not immerse the coating equipment and connecting/extension cables and hoses, etc. into a
cleaning solvent. Since the electrostatic coating equipment is electric machinery, if it is immersed
in a cleaning solvent needlessly, it may cause a failure.

21. Do not wire the connecting/extension cables and hoses on the floor but hang them from the
ceiling or side walls as much as possible to prevent their breakage due to scratches, etc. (When
conductive paint is used, be sure to hand the coating hoses using rubber tubes or other
insulators.)

22. The coating booth and exhaust system (duct, fan) must be always kept clean; it should be
cleaned at regular intervals. If there is paint waste in the coating booth and exhaust system when
fire occurs, it may cause spread of fire and large damage.

23. Make sure that the tip of the nozzle is at least 150 mm away from the work piece subject to paint
spraying. Generally, the electrostatic coating equipment has a structure to automatically lower the
potential of the nozzles when they come close to ground. However, in the case of a paint supply
system using an insulating stand, the potential of the nozzles is not lowered to that of the pump,
and it may cause large sparks. Taking into consideration contingencies such as swinging and fall
of the work piece, paint it as keeping a sufficient spray distance.

24. Drain the air transformer and air compressor, etc. thoroughly. If air contains moisture, it may
cause a coating failure or go off a warning buzzer and activate the safety circuit. Pay due attention
to remove moisture.

25. If the paint feeder uses an insulating stand, the paint feeder must be located at least 500 mm
away from the other objects around it. When you touch the insulating stand, be sure to turn off the
electrostatic controller and firmly contact the grounding stick to the insulating stand before
touching it. Low electric resistance paint conducts as much electricity as a copper wire does.
Therefore, if the paint comes in contact with the paint container, you may encounter an electrical
shock. Take a safety measure by installing grounded safety fences in the place exposed to a
passage so that they are not touched by mistake.

26. Install an extinguisher which is regularly inspected and has a sufficient extinguishing capability in
the working area against an electrostatic accident.

27. Do not spray paint to human. Paint may gush out by residual pressure after the operation, not to
mention in the state where paint and air are under pressure. Check that the trigger valve is closed
when the operation is not performed so that paint will not gush out by careless operation.

28. Check that paint and air are not leaked before starting the operation. Check the equipment
frequently while using the equipment so that an accident will not occur due to a loosened screw,
etc.

29. For use and installation of this equipment, be sure to comply with the present regulations.

4
2.1
2 Equipment Overview

Names and Roles of Parts

2.1.1 Names and roles of main unit parts

Retaining nut
Fix the air cap to the tip of
the gun.

Paint Nozzle

Spray paint
Gun bracket
Fix the gun to the actuator

Air cap (sold separately)

Charge electrode
Atomize paint sprayed from the paint
Apply high voltage to paint. nozzles and form the spray pattern.

Cable Connector
Connect Cable and gun

Shroud
Removable cover to protect inside of the gun Plug
The return line is blocked when the
equipment is used in the
non-circular mode.

5
2.2 Names of Connections on Back Plate

『TA』：Paint Valve Operate Air

Cable
OD6 ㎜-ID4 ㎜

『PA』：Pattern Air 『AA』：Atomizing Air

OD8 ㎜-ID6 ㎜/Rc（R）1/4 OD8 ㎜-ID6 ㎜/Rc（R）1/4

『F.IN』
：Paint In 『F.OUT』
：Paint Out

※ For Paint circulate・Drain

Valve paint leakage hole

2.3 Items on Rating Plate

Label

6
2.4 Component of Gun (Main Body)
① Sungun III automatic electrostatic air spray gun (EAB400)
The gun (main body) is equipped with the power pack (high-voltage generator) and has air and
paint lines of the paint discharge valve (trigger valve).
This product is in the non-circular mode in the default setting. To use the product in the circular
mode, you need to replace the plug with the supplied part.
② Paint nozzle
The paint nozzle has a role to discharge paint from the tip of the gun and switch pattern air and
atomizing air.
③ Charge electrode
The charge electrode applies high voltage to the paint discharged from the tip of the gun to perform
electrostatic coating.

2.5 Related Accessory Parts (Optionally Available)

● The related accessory parts and maintenance tools are necessary for running and operation of this
product. Select appropriate equipment from those listed below according to the usage and
conditions and procures them separately.
● When you procure products and/or parts of the related accessory equipment, be sure to check the
part numbers and quantities in the relevant instruction manuals.

2.5.1 Air cap (Model: HN Series)

● A part which is mounted at the tip of the coating equipment and enables atomization and pattern
formation using power of air.
● Select an air cap from the table below with the specifications which meet your usage.
Image Figure of HN Series Air Cap

HN Series Air Cap

*All the HN Series caps can be used for common Paint Nozzle Assy.

<How to Select Air Cap>

Part No. of air cap

Pattern width (mm)

Model Usage Parts No.

HN400 Narrow pattern 15F8-001
HN600 General 15F8-101
HN800 Fine atomization 15F8-201

Paint discharge rate (mL/min)

7
2.5.2 Electrostatic controller (BPS260 Series)
● A device to control high-voltage application of the built-in cascade of the coating machine.
It also detects and outputs various errors by monit O Ring the current value while the equipment is in
operation.

External View of BPS260 Series

*For details of the specifications, see the instruction manual of BPS260

Electrostatic controller part No. list

No. Part Name Parts No. Specifications
1 445-0159 English/Japanese Ver.
BPS260
2 445-0160 English Ver.

2.5.3 Power transmission cable

● You can connect the “connection cable” and “extension cable” up to 30 m between the coating
equipment and electrostatic controller and use them as a power transmission cable.

Connection cable part No. list

No. Part Name Parts No. Specifications
1 Connection cable 2552 10 m

Extension cable part No. list

No. Part Name Parts No. Specifications
1 2549 10 m
Extension cable
2 2549-1 20 m

8
Cable Image

Controller
Extension Cable :2549 =10m
:2549-1=20m

Cable :2552=10m
Gun

2.5.4 Paint hose

● A paint hose to feed paint from the pump to the paint equipment.
These hoses have a double-layered structure; they can be used with paint with a low electric
resistance value.

Paint hose (metal fitting specifications) part No. list

No. Part Name Parts No. Specifications
1 Paint hose 3445 1m
2 Paint hose 3445-1 5m
3 Paint hose 3445-2 10 m

Paint hose (resin fitting specifications) part No. list

No. Part Name Parts No. Specifications
1 Paint hose 3446 1m
2 Paint hose 3446-1 5m
3 Paint hose 3446-2 10 m

9
2.5.5 Connection 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.

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. (Grounding resistance should be under 1kΩ)

10
 3 Specifications

3.1 Outline Drawing

3.2 Product Specifications

Model EAB400
Dimensions Φ75 × 239 mm
Weight 1,400 g *Including the paint nozzle and plug; The paint hose and gun bracket are excluded.
Maximum hydraulic pressure 0.6 MPa
Maximum air pressure 0.6 MPa
Maximum voltage applied DC-60kV
Maximum current 80 μA
Minimum working pressure: 0.35 MPa
Trigger valve working pressure
Normal working pressure: 0.4 to 0.5 MPa
Applicable air cap HN400/HN600/HN800
Electrostatic controller BPS260 series
10 m
Connection cable length
*The connection cable can be extended up to 30 m in combination with an extension cable.
Environment Temperature: 5 to 40°C; Humidity: 40 to 80%
Solid particle size: 0.1 μm or less
Dew point under pressure: 10°C
Supply air conditions
Atmospheric dew point: -17°C
Remaining oil: 0.01 mg/m3

NOTICE
Do not use a paint heater. The temperature of the paint must be 40°C or lower when
it is supplied. If the temperature of the paint is high, the paint hose may soften and
come off.

NOTICE
For the paint pressure feed system and paint regulator, refer to their instruction
manuals. The paint feeding pressure must be 0.6 MPa or lower.

11
 4 Precautions before Operation

The Sungun III system was designed with particular emphasis on safety. However, it is intended for use in a
place containing flammable gasses. Great care must be taken when handling/operating it.

WARNING
● Make sure that the work piece subject to coating is constantly grounded.
(If object is metal, under 1 kΩ, and if object is plastic, under 1 MΩ.)
However, if any paint adheres to its contact area with the hanger, its conductivity may lower and a lot
of electrostatic energy could be accumulated, resulting in a fire due to a spark. Remove any paint
from hangers at regular intervals.

● All metal objects inside the coating booth must be grounded.

High voltage is applied inside the coating booth. If any metal object fails to be grounded inside the
booth, electrostatic energy could be accumulated, resulting in a fire due to a spark.

● Do NOT bring the work piece subject to coating in contact with the nozzle attached to the automatic
electrostatic air spray gun.
If the work piece subject to coating is not correctly suspended, or if it approaches the nozzle due to
vibration of the conveyor, a fire may be induced by a spark. In particular, if an insulating stand is
used, intense sparks will occur; provide a large enough distance for spraying.

● If using an insulating stand, the paint feeder must be located at least 300 mm away from the other
objects around it.
Low electric resistance paint conducts as much electricity as a copper wire does. If the paint used
comes in contact with a metal object such as the paint container, you may encounter an electrical
shock. If the automatic electrostatic coating equipment is located near the walk space, a grounded
safety fence should be provided.

● Wear antistatic shoes (approx. 1 MΩ electric resistance) throughout operations.

If you wear rubber soled or synthetic resin soled shoes, you may encounter an electrical shock when
you touch a grounded object.

● Make sure that the ventilation system is in operation during paint spraying.
Paint and solvent are subject to the hazardous materials regulations of the Fire Defense Law (they
are designated as class 4 hazardous materials). The gasses generated by paint spraying are
defined as explosive gasses (explosion class 1) under the factory explosion proof guideline.
Operations must be performed with an appropriate ventilation system in operation.

● Do NOT leave paint nor solvent unattended in the coating booth.

Paint and solvent are subject to the hazardous materials regulations. They must be stored in a
cabinet that conforms to the regulations. In particular, cleaning solvent must be stored in a grounded,
lidded container.

● Provide a fire extinguisher.

Be sure to keep a powder type, carbon dioxide fire extinguisher handy in case of emergency.

12
 5 Preparation for Coating

Before starting the coating operation, make preparations for coating in accordance with the following procedures.

CAUTION
Check that the power switch of the static electricity controller is OFF.

5.1 Paint
① Mixing of paint
This equipment can obtain an electrostatic effect from almost all synthetic resin paints, except some
paints, and therefore there is no need to mix paints specially. Meanwhile, you can obtain a higher
electrostatic effect by adjusting the electric resistance value of the solvent in some cases. In addition,
much electrostatic effect cannot be expected from some paints with extremely low or high electric
resistance value. Check the resistance value using a paint resistance meter.
If the paint resistance value is adjusted within 15 to 70 MΩcm, a fair effect can be obtained in most cases.
When the resistance is 15 MΩcm or lower, even if a fair electrostatic effect is obtained, if the booth is not
ventilated properly, paint is sprayed back to the gun.

NOTICE
You can judge if an electrostatic effect is good or bad by coating a φ20 to 30 mm steel
pipe from the front as it is grounded. If coating is done up to the back side, it indicates
that a good electrostatic effect is obtained.

CAUTION
From conductive paints such as metallic paint and water paint of which electric
resistance is extremely low, almost no electrostatic effect can be expected unless
paint supply system using an insulation stand.
When this kind of paint is used, the high voltage shutdown circuit of the static
electricity controller is activated upon application of high voltage, and an alarming
buzzer goes off and high voltage is shut down. When you turn OFF the power switch
of the static electricity controller, the alarming buzzer is reset.

CAUTION
Be sure to use a paint and solvent of which flash point higher than the room
temperature by 5°C or more and turn on the ventilation system.

NOTICE
If you do not know the compatibility between the gun/equipment and paint, please
consult our company.

13
② Insertion of paint
Insert paint into the paint feeder.
The standard viscosity when this coating equipment is used is around 9 to 30 sec/FC#4 in general, but
the viscosity varies according to various conditions such as the type of paint and solvent, shape of the
work piece subject to paint spraying, and thickness of a coating film, etc.

③ Supply of paint (For the operation, see the instruction manual of your paint feeder.)
If there is any residual air in the paint hoses, spraying performance will not stabilize due to inefficient
spraying; remove any air from the hoses.

④ Discharge of paint
Discharge paint from the tip of the gun. Turn ON the paint valve without supplying air to the gun to
discharge paint from the tip of the gun. If there is any residual air in the paint hoses, spraying
performance will be deteriorated; discharge paint until all air is removed from the hoses.

⑤ Adjustment of the quantity of paint sprayed

Set the operation mode selector switch on the control panel to "Manual," set the open/close paint switch to
"On," and increase the air regulator pressure for adjustment of the quantity of paint sprayed. Adjust the
quantity of paint sprayed to the specified level while paint flows from the nozzle.
If low-viscosity paint is sprayed in small quantities, insertion of an orifice (separately sold) between the
automatic electrostatic air spray gun system and nozzle will facilitate adjustments.

14
5.2 Adjustment of Air

① Adjustment of atomizing air

Check the atomization state of paint discharged from the gun.
Open the trigger valve and set the air pressure to be supplied to the gun to 0.2 to 0.3 MPa (target) to
atomize paint.
To adjust the atomizing air pressure, set the operation mode selector switch on the control panel to
"Manual" and set the atomizing switch to "On," and operate the atomizing air pressure regulator at the
bottom of the control panel. Adjust it while the air cap discharges air.
While the atomization air pressure is within 0.05 to 0.35 MPa in general when using a flat spray nozzle,
adjust the air pressure in accordance with the air cap and target finishing state.

② Adjustment of pattern air

Adjust the pattern width of the atomized paint.
To adjust the pattern change air pressure, set the operation mode selector switch on the control panel to
"Manual" and set the atomizing switch to "On," and operate the pattern change air regulator at the
bottom of the control panel. Adjust the spray pattern width while spraying paint.

15
5.3 Spraying Distance
The spraying distance should be 150 mm or more between the tip of the nozzle and the work piece subject
to paint spraying when they are located closest to each other and the coating equipment should be located
ahead of the front of the reciprocator.
If the distance is too large, adhesion performance will lower. Conversely, if it is too small, sparks may be
generated.
The optimum spraying distance is 250 to 300 mm.

5.4 Travel Speed

The travel speed of the reciprocator depends on the required coating film thickness. In general, it ranges
from 15 to 45 m/min.
If the required coating film thickness cannot be obtained even at a higher speed than 50 m/min, some extra
automatic electrostatic air spray guns or some extra paint heaters should be added. In such cases, please
contact our Coating Engineering Department. (If the travel speed is increased, transfer efficiency will lower; it
is not recommended).

5.5 Paint Spray Cut

The reciprocator stroke is kept at a constant level. Prevent unnecessary paint from being sprayed in
consideration of the length or width of the work piece subject to paint spraying.
To adjust the spray cut, change the setting on our reciprocator control panel as seeing the spray state.

5.6 Voltage Applied

Electrostatic pressure should be adjusted in consideration of the material of the work piece subject to paint
spraying as well as of the type of the paint used. In general, it ranges from approximately -50 to -70 kV. It
ranges from approximately -40 to -60 kV, -30 to -50 kV or -40 to -90 kV in the case of a metallic paint, a
water-based paint or a wooden product, respectively.

5.7 System Operation Procedures (they differ according to the specifications of the system; Operation
procedures with standard specifications are described below.)
① Manual operation
・ Turn on the power. Set the breaker inside the panel and make sure that the "Power" indicator lamp
is on. If a door switch is used, make sure that it is closed.
・ Set the operation mode selector switch to "Manual." Check the "Manual" indicator lamp.
・ Set the operation mode selector switch to "Coating."
・ Discharge atomizing air and pattern change air. Set the atomizing switch to "On." Make sure that the
"Atomizing" indicator lamp is on.
・ Discharge paint. Set the paint switch to "On." Make sure that the "Paint" indicator lamp is on. Use
the air regulator at the bottom of the control panel to adjust the atomizing air pressure, pattern
change air pressure, and quantity of paint discharged.

16
 ・ Press the "Start" switch for the reciprocator. Make sure that the "Reciprocator" indicator lamp is on.
・ Supply high-voltage power.
Set the controller power switch at the central front of the control panel to “On.” At this point, make
sure that the controller's power lamp (green) is on. Next, press the high-voltage pushbutton switch
"On" at the upper front of the control panel.
At this point, make sure that the "High pressure" indicator lamp and the controller's high pressure
lamp (red) are on.
・ Start coating operations.

② Automatic operation
・ Turn on the power. Set the breaker inside the panel and make sure that the "Power" indicator lamp
is on. If a door switch is used, make sure that it is closed.
・ Set the operation mode selector switch to "Automatic."
・ Set the operation mode selector switch to "Coating."
・ Make sure that the atomizing switch is “On.”
・ Make sure that the paint switch is “On.”
・ Press the "Start" switch for the reciprocator. Make sure that the "Reciprocator" indicator lamp is on.
・ Supply high-voltage power. Set the controller power switch at the central front of the control panel to
“On.”
At this point, make sure that the controller's power lamp (green) is on. Next, press the high-voltage
pushbutton switch "On" at the upper front of the control panel. At this point, make sure that the "High
pressure" indicator lamp and the controller's high pressure lamp (red) are on.
・ Start coating operations.

5.8 Precautions to Be Taken at Stoppage and End of Spraying Operations

① Cleaning the paint nozzle

When stopping spraying operations, or at the end of spraying operations, be sure to clean the nozzle.
・ Press the high-voltage pushbutton switch "Off" to turn off the high-voltage power.
・ Bring the reciprocator to a stop to turn off the paint and air spray.
・ Bring the ground bar connected to the tip of the paint nozzle in complete contact for more than 10
seconds to thoroughly discharge any residual electrostatic energy.
・ Use a brush soaked (horsehair/animal/vegetable bristle brush) with solvent to dissolve and remove
the paint attached to the nozzle surface.
If paint cannot be removed with the brush, submerge the nozzle in solvent for a few minutes and
then retry to remove it carefully with the brush without causing damage to the nozzle.
・ After it has been cleaned, discharge atomizing air manually to remove any solvent trapped in the air
line.

17
② Cleaning the paint hoses, automatic electrostatic coating equipment, and air control paint regulator
In the case of paint color change, or if you are not using the coating equipment for a long period of time,
clean the inside of the paint line.
・ Press the high-voltage pushbutton switch "Off" to turn off the high-voltage power.
・ Bring the reciprocator to a stop to turn off the paint and air spray.
・ Set the operation mode selector switch to "Cleaning."
・ Select the manual mode and operate the paint pump with no load to remove any residual paint from
the paint line (use of pressurized air will help finish this operation in a shorter period of time).
At this point, make sure that the high-voltage power is turned off.
・ Open the pump's three-way cock to remove any residual paint from the paint hoses, air control paint
regulator, and automatic electrostatic coating equipment. After the removal, close the cock.
・ Transfer the suction pipe from the paint pump to the solvent tank and circulate solvent through the
paint line without allowing it to flowing from the tip of the automatic electrostatic coating equipment
(perform this step a couple of times using clean solvent).
・ If you are not using the coating equipment for a long period of time, completely remove any residual
solvent from the paint line; or thoroughly fill the paint line with clean solvent.
・ Wipe any dirt from the surface of each equipment using a cloth soaked with solvent. Do NOT clean
inside of the gun with its shroud removed.

WARNING
● When cleaning the nozzle, make sure that the high-voltage switch is OFF.
● In the case of paint with a low electric resistance value, be sure to use an insulating stand.
Otherwise, the expected electrostatic effect could not be obtained. In general, an insulating stand
should be used, if the electric resistance value of the paint is 20 MΩ-cm or lower with the voltage
setting = -70 kV, or if the reading on the high-voltage generator's ammeter is -50 μA or higher.
● Operators must maintain a distance of more than 1 m from the coating equipment during spraying
operations. If you move closer to the coating equipment, you may get an electrical shock.
● Do NOT put solvent containers inside the coating booth.

CAUTION
● A nozzle is an essential part of a coating system. When handling nozzles, great care must be taken
so as not to drop them or cause damage to them.
● Be sure to drain the air compressor once a day.
Replace the cartridge elements for the air filter and the mist separator once every 6 to 12 months.
● Paint must be filtered before use.
● Do NOT use the gun with its shroud removed.
● If a two-component paint or an easily perceptible paint is used, thoroughly clean the inside of the
gun to remove any residual paint after use.
If it fails to be thoroughly cleaned, the durability of the bellows in the valve may lower and paint
leakage could occur as a result.

18
 Definition of an Overcurrent
The high-voltage charging part of the coating equipment is protected with an insulating material.
If its insulation performance lowers due to foreign matter, such as paint, adhered to its surface, current
may flow from the high-voltage charging part through the paint adhered to the surface, resulting in a
dangerous situation such as occurrence of a spark. This is a typical process of occurrence of an
overcurrent.
Current leaking from the high-voltage charging part is monitored by an overcurrent protection circuit. If
the current setting is exceeded, the overcurrent protection circuit will bring the output from the
high-voltage generator to a stop to prevent accidents due to electrostatic energy. The activation of this
circuit is regarded as an overcurrent.
If an overcurrent occurs, necessary safety measures including alarm output and coating line stoppage
will be taken. To return to normal operation, you will have to restore the insulation as well as to locate
the part(s) with poor insulation.

19
 6 Maintenance and Inspection
Keep the gun, paint hoses, and connection cables clean without affixing paint and other dirt on them.
Be careful not to damage them with mechanical shock.

6.1 Procedure to Finish Operation

To stop or finish the coating operation, follow the procedures given below.
6.1.1 When the operation is resumed within 24 hours
(1) Turn OFF the power switch on the control panel.

CAUTION
In the case of a paint with a low electrostatic resistance value (2 MΩcm or less), the
paint pump will be charged with high voltage. Be sure not to touch the pump while high
voltage is being applied.
When you touch the pump or replenish the paint, turn OFF the static electricity
controller and ground the pump with the ground bar.

(2) Set the pressure of the air to be supplied to the gun to 0 MPa.

(3) Set the drive air pressure of the paint pressure feed system to 0 MPa.

(4) Discharge the paint from the tip of the gun to discharge the remaining pressure.

(5) Quietly ground the electrode pin at the tip of the paint nozzle to discharge any residual electrostatic
energy as the trigger is open.

Ground body

20
(6) Turn the retaining nut counterclockwise and remove it, and also remove the air cap.
Be careful when you remove the air cap so that thinner and solvent will not enter inside the gun.

CAUTION
Be careful not to drop the air cap when you remove it.
If you drop the air cap, it may get damaged.

WARNING
It may cause injury to the human body and an accident.
When you remove the air cap, be sure not to touch the electrode pin.

CAUTION
It may cause breakage of the retaining nut, nozzle, and equipment.
When you remove the retaining nut, be sure to turn it with your hand.
If you use a tool, etc. to remove the retaining nut, it may get damaged.

(7) Remove the dirt such as paint mist affixed on the gun and air cap with a waste cloth moistened with a
cleaning solvent.

CAUTION
When you clean the gun and air cap, do not use a hard brush such as a metal brush.
If you use a hard brush, the surface of the gun and air cap gets scratched, and their
performance may be deteriorated.

CAUTION
Close the gun paint adjustor when the operation is not performed so that paint will not
gush out by careless operation.

21
 CAUTION
When you clean the nozzle and air cap, be careful so that a solvent will not enter the
inside of the coating equipment. After cleaning is finished, pull the trigger to discharge
air and discharge entered solvent.

CAUTION
Entry of solvent may cause an overcurrent during electrostatic pressure application,
making it impossible to perform electrostatic coating.
Electrostatic leakage due to paint adhered to the surface of the gun may cause
overcurrent, making it impossible to perform electrostatic coating.

CAUTION
Do not leave the gun, power cables, and hoses, etc. in a solvent while cleaning is made
and after cleaning is done, or after the operation is finished. The gun contains a lot of
electric and electrical circuits and has a structure in which a solvent will not enter under
normal use.
However, if it leaves in a solvent for a long time, the durability may be deteriorated,
causing a failure.

CAUTION
If a chemically curing paint such as a two-component paint or an easily perceptible paint
is used, clean the inside of the gun every time the operation is finished in accordance
with “6.1.2 When the operation is not resumed within 24 hours”.

WARNING
If you use the gun covered with a sheet for prevention of contamination, a spark may
occur due to electrostatic pressure application, resulting in a fire.

CAUTION
If the gun is installed in an upward inclined position, clean it while discharging
atomizing air and pattern air at a low pressure of 0.5 MPa or so.
Entry of a conductive paint, such as a metallic paint, may cause electrostatic leakage,
making it impossible to perform electrostatic coating.

22
 (8) At least once a week, remove the shroud and check its inside for foreign matter such as paint or
solvent. If there is any paint inside, remove it with solvent, completely remove any residual solvent
with air blows, and then attach the shroud.

CAUTION
Do NOT perform coating operations with the shroud removed. This may cause paint
mist to adhere to the inside of the shroud, resulting in overcurrent.
Do NOT apply electrostatic pressure with the shroud removed. This may decrease the
withstand voltage performance of the gun and a voltage breakdown could occur,
resulting in overcurrent.

(9) Before the start of daily operations, make sure that the cables connected to the gun is free from
damage. In addition, make sure that any excessive tension will not be applied on the cables due to
the movement of reciprocator.

CAUTION
Some cables are connected to the gun: gun power cable, gun ground cable, and
control cable.
If any of them are damaged, you may encounter a fire or an electrical shock due to a
ground fault.

(10) Before the start of daily operations, make sure that the metal parts, such as the gun's mounting
bracket, are correctly grounded. Measure the resistance between gun's bracket and a grounded object
such as the booth; it must be 10 Ω or lower.
(11) Before the start of daily operations, make sure that the gun is firmly secured and that the gun does not
come into contact with the work piece subject to paint spraying.

6.1.2 When the operation is not resumed within 24 hours

(1) Turn OFF the power switch on the control panel.
(2) Set the pressure of the air to be supplied to the gun to 0 MPa.
(3) Pull out the suction pipe of the paint pump from the paint container.
(4) Drive the paint pump and discharge the paint from the paint return line.
(5) Open the trigger valve of the gun to discharge the paint remaining in the hoses and gun from the tip of the
gun.
(6) Suck a cleaning solvent from the suction pipe, discharge it from the return side to the cleaning waste
container, and repeat this procedure until the inside of the pump becomes clean.
(7) Discharge the solvent from the tip of the gun to clean the hoses and inside the gun.
(8) Stop the pump and open the trigger valve to discharge the residual pressure from the tip of the gun.
(9) Turn the retaining nut counterclockwise and remove the air cap.
(10) Remove the dirt such as paint mist affixed on the gun and air cap with a waste cloth moistened with a
cleaning solvent.
(11) Rotate the hex of the nozzle using the dedicated spanner as pulling the trigger of the gun and remove
the nozzle.

It is recommended to leave the cleaning solvent in the line after cleaning is finished to prevent the
remaining paint in the paint line from being hardened.

23
 CAUTION
The paint nozzle may be damaged.
When you remove the nozzle, be sure to use the dedicated spanner, which is an
attached part. Be careful not to drop the nozzle.

(12) Dip the paint nozzle in the cleaning solvent and blow the compression air to the nozzle to blow off the
dirt.

CAUTION
When you clean the paint nozzle, do not poke it with a metal object such as a wire.
Do not use a metal brush and the like. If you do so, it may expand the hole diameter
and/or make scratches, deteriorating the performance.

CAUTION
Wait 10 sec or more after turning OFF the power switch of the static electricity
controller before cleaning the gun. 90% or more of fire accidents of the static electricity
coating equipment occurred upon cleaning of the nozzle, etc. When you clean the
nozzle, etc., be sure to turn OFF the power switch.
Provide a fire extinguisher in case of a fire accident.

CAUTION
When an error occurs during the operation, turn OFF the power switch of the static
electricity controller and lower the pressure of the air and paint to be supplied to the
gun to 0 MPa.

CAUTION
Do not give a strong shock such as drop, etc.
Although this equipment is designed fully taking into consideration strength, it may get
damaged by shock.

(13) Regarding the cleaning waste solvent, collect and reuse it using the Solvent Recovery Device or dispose it
through an industrial waste disposal contractor in accordance with the law.

24
6.2 Maintenance of Other Equipment
(1) For maintenance of the paint feeder, refer to its instruction manual.
(2) At the end of daily operations, clean the resin portion of the air control paint regulator's mounting
bracket with solvent to remove any paint.

CAUTION
Adhesion of a lot of paint to the surface of the air control paint regulator's mounting
bracket may cause charging current to leak, resulting in an overcurrent.

(3) If a two-component paint or an easily perceptible paint is used, thoroughly clean the gun with solvent
after use. Disassemble and clean it at regular intervals (at least once every three months).

6.3 Periodical Inspections

Conduct inspections regularly in accordance with the table in the next page so that the performance of this
equipment can be fully utilized. The frequency of each inspection is a reference and varies according to
the use condition.

WARNING
Unexpected operation of the coating equipment may cause injury to the human body
and an accident.
Before conducting a periodic inspection, turn OFF the power of the control panel and
release air and pressure.

25
 Item Procedure Frequency
Inspection of exterior of the gun When paint is affixed on the gun, wipe it with a soft cloth or brush
moistened with a cleaning solvent.
If there is any scratch on the gun, replace the gun with a new one.
Inspection of waste paint from air cap When paint is affixed on the air cap, wipe it with a soft cloth or
brush moistened with a cleaning solvent.
Inspection of clogging of air cap air Dip the air cap in a cleaning solvent and blow it with air.
discharge hole If clogging cannot be removed, replace the air cap with a new
one.
Inspection of scratches and dents If there is any scratch and/or dent on the paint nozzle, replace it
around the paint outlet of the paint with a new one.
nozzle
Inspection of clogging of the paint Dip the paint nozzle in a cleaning solvent and blow it with air to Every day
discharge hole of the paint nozzle remove clogging. If clogging cannot be removed, replace it with a
new one.
Inspection of paint seat and bellows Perform cleaning from the gun paint line to the nozzle by pouring
needle a cleaning solvent, and if paint is leaked from the tip of the gun,
replace the paint seat or bellows needle.
Check current value when If the current value is higher than the normal value, identify the
electrostatic pressure applied. location where current is leaked and replace the part.
Inspection of charge electrode If the distance between the electrode and paint discharge hole of
the nozzle is less than 2 mm, replace the electrode with a new
one.
Inspection of connection cable If the connection cable is damaged, replace it with a new one.
Inspection of air leakage If air is leaked, replace the seal at the air leakage location.
Inspection of contamination with paint If the inside the paint hose is contaminated with paint, perform
in paint hose cleaning by pouring a cleaning solvent.
If clogged paint cannot be removed, replace the hose with a new Every
one. month
Inspection of trigger valve If paint leaks from the tip of the gun, replace the trigger valve.
Inspection of piston When there is a problem in sliding ON/OFF of the trigger valve,
replace the piston with a new one.

NOTICE
For how to replace parts, see “9. How to Replace Parts”.

CAUTION
Do not disassemble the gun unnecessarily when an error occurs.
You should not disassemble the gun to maintain the electric insulation and sealing
functions of the gun unless there is a need to replace a part due to an error.

CAUTION
The surface of the gun may get warm by heat of the high-voltage generator. This is not
a failure.

26
6.4 Consumable Part
Prepare spare parts in accordance with the use condition with reference to the rank category in the
consumable parts list given below.
Estimated
Publishing
Rank Part name Part No Consumption Component assembly
page
Period

Paint Nozzle Assy 15F7 6 months EAB400 35･36

A Charging Electrode 1718 6 months EAB400 35
O RING 130-9012 6 months Paint Nozzle Assy 36
Paint Seat 1728 12 months EAB400 35･36
Needle 1832-008 12 months EAB400 35
U PACKING 152-0004 12 months EAB400 35
B
O RING 101-9014 12 months EAB400 35
Ring Seal 373-0010 12 months Retaining Nut Assy 36
O RING 130-9006 12 months Paint Seat 36
O RING 101-9004 － EAB400 35
O RING 102-9065 － EAB400 35
O RING 130-9010 － EAB400 35
O RING 130-9042 － EAB400 35
Cross Recessed Screw 364-0019 － EAB400 35
C
Hex Socket Screw 364-0030 － EAB400 35
Plug 131E-002/131F- － EAB400 35
Hex Socket Screw 03-70520 － EAB400 35
Gasket 137F-034 － EAB400 35
Sems Screw 2P 12-10204 － EAB400 35
O RING 130-9004 － EAB400 35
D O RING 101-9007 － EAB400 35
O RING 101-9005 － Paint Seat 36

Rank A: Daily consumable parts Rank B: Medium-term consumable parts

Rank C: Parts that may get damaged/lost upon Rank D: Parts that need to be replaced upon

disassembling disassembling

*Note that the durable periods of the consumable parts vary according to the paint and facilities conditions, etc.
The values given in the above consumable parts list are reference values in the case that the equipment is
operated for 20 days/month and 8 hours /day.

27
 7 Paint Problems and Solutions
There are cases where multiple symptoms and causes occur at the same time according to the state of a paint
problem.
Symptom Cause Countermeasure
1. Poor spray ① The atomization air pressure is too ②
Increase the atomization air
atomization low. pressure.
② Quantity of paint discharged is too ② Reduce quantity of paint discharged or
large. increase the atomization air pressure.
③ Paint viscosity is too high. ③ Lower paint viscosity.
④ The pin at the tip of the nozzle is ④ Replace the charge electrode.
bent.
⑤The paint nozzle is damaged. ⑤ Replace the Paint Nozzle Assy.
⑥ The solvent is not appropriate. ⑥ Consult the paint manufacturer or us.
2. Excessive paint ① The spraying distance is too far. ① The spraying distance must be within 150 to
splashes 200 mm.
② The atomization air pressure is too ② Adjust the atomization air pressure to lower.
high.
③ The paint resistance is too low. ③ Adjust the paint resistance to within 15 to 70
Ω-cm).
④ Grounding of the work piece subject ④ Provide complete grounding.
to paint spraying is not complete.
⑤ The discharge speed is too slow. ⑤ Increase the discharge speed.
① Ground fault with work piece subject ① Clean the paint affixed on the hanger and
3. Poor coating
to paint spraying. provide complete grounding.
efficiency
② The atomization air pressure is too ② Adjust the atomization air pressure to an
high. appropriate level.
③ The spraying distance is too far. ③ The spraying distance must be within 150 to
200 mm.
④ Applied voltage is too low. ④ Increase the output voltage of the static
electricity controller using the output voltage
adjustment switch.
⑤ The charge/discharge speed of the ⑤ Adjust the charge/discharge speed of the
booth is too fast. booth to lower.
⑥ Paint electric resistance is too high. ⑥ Adjust the resistance to within 15 to 70
MΩ-cm.
4. ”Whiskers" ① Solvent vaporizes too quickly. ① Use lower volatility solvent or additive.
generated due to
paint attached to ② The paint has a high viscosity. ② Lower paint viscosity.
nozzle, or filiform
lumps generated
on a work piece
subject to paint
spraying.

5. Granulated paint ① Poor spray atomization. ① See “Poor atomization” in 1 of this chapter.
surface ② There is much dust in the coating ② Put dust filter at the air intake duct leading
booth, and dust is affixed on the to the coating booth and remove dust with
paint surface. air blows.
③ Contamination of atomized air ③ Clean or replace the filter of the air line.
④ Unevenly distributed pigment is ④ Change the solvent or filtrate the paint
contained in paint. thoroughly.
6. Orange peel ① The temperature in the paint booth is ① Adjust the room temperature or use lower
(spots/marks) high, or the solvent evaporates fast. volatility solvent.
② Temperature of work piece subject to ② Adjust the drying furnace to lower the
paint spraying is too high. temperature of the work piece subject to
paint spraying.
③ The charge/discharge speed is too ③ Adjust the speed in the range from 0.5 to
fast. 1.0 m/s on the surface of the work piece
subject to paint spraying.

28
 Symptom Cause Countermeasure
7. Crawling ① Incompletely cleaned work piece ① Perform cleaning thoroughly or remove oil
subject to paint spraying. thoroughly.
② Contamination of atomized air ② Clean or replace the filter of the air line.
③ Baking oven exhaust failure. ③ Make exhaust system operate correctly.
8. Sagging of paint on ① Coating film is too thick. ① Reduce the paint discharge amount or
increase the gun travel speed.
the paint surface
② Paint viscosity is too low. ② Increase paint viscosity.
③ Solvent vaporization is slow. ③ Use higher volatility solvent.
9. See-through of ① Insufficient paint is discharged. ① Adjust the quantity of paint sprayed and
consider the travel speed of the gun and
coating film
recoating.
② Paint viscosity is too low. ② Increase paint viscosity.
10. Pinholes ① Contamination of atomized air ① Clean or replace the filter of the air line.
② Solvent vaporizes too quickly. ② Use lower volatility solvent.
③ Temperature of work piece subject to ③ Lower the temperature.
paint spraying is too high.
④ Incompletely dried undercoating. ④ Completely dry.
⑤ Setting time is short. ⑤ Take sufficient setting time.
11. Blushing ① Temperature and humidity inside and ① Use lower volatility solvent.
outside of the paint booth are high. Inspect air-conditioning equipment.
(whitening).
② Inappropriate solvent selected. ② Consult the paint/solvent manufacturer or
us.
12. Bubbles (foaming) ① Contamination of atomized air ① Clean or replace the filter of the air line.
② Incompletely dried after wet rubbing. ② Completely dry.
③ Coating film is too thick. ③ Reduce the paint discharge amount.
④ Solvent vaporizes too quickly. ④ Use lower volatility solvent.
⑤ Temperature of the baking oven is ⑤ Adjust the temperature to an appropriate
too high. value.
13. Inappropriate ① Paint and/or dust is affixed to ① Perform cleaning thoroughly using thinner
atomized air of the paint nozzle and and a bamboo brush and filtrate the paint.
pattern shape
to the paint discharge outlet.
② The paint has a high viscosity. ② Lower the viscosity.
③ The tip of the paint nozzle is ③ Repair or replace nozzle.
damaged.
④ Pattern adjustment failure. ④ Adjust the pattern correctly.
⑤ Incompletely tightened nozzle. ⑤ Confirm that the Paint Nozzle Assy is not
loosened and then mount the air cap.

29
 8 Troubleshooting

There are cases where multiple symptoms and causes occur at the same time according to the state of a
failure.

Symptom Cause Countermeasure

1. Paint discharge is ① The Paint Nozzle Assy is not tightened ① Tighten the Paint Nozzle Assy firmly.
unstable, and spray firmly.
performance ② The seat face of the paint seat or bellows ② Replace the paint seat or bellows needle.
becomes needle is damaged.
insufficient. ③ Air is mixed into the paint. ③ Check the paint feed system.
④ Quantity of paint discharged is extremely ④ Increase the paint discharge amount or
low. lower the atomized air pressure.
2. The paint ① Failure in the paint pressure feeding ① Check the paint pump, paint regulator,
discharge amount system and other paint supply system.
is decreased. ② Clots of paint and/or dust is clogged in ② Clean the paint seat unit.
the paint seat unit.
③ Paint and/or dust is affixed in the Paint ③ Remove the Paint Nozzle Assy and clean
Nozzle Assy. it.
① Clots of paint and/or dust is clogged in ① Clean the paint seat unit.
3. Paint leaks from
the paint seat unit.
the nozzle.
② Wear-out and chipping of the paint seat ② Replace the paint seat or bellows needle.
unit.
③ Wear-out of piston spring ③ Replace the spring in the piston unit.
④ The pressure feeding pressure of the ④ Lower the pressure feeding pressure.
paint is too high.
4. Paint leaks from ① Damage of the packing ① Replace the bellows packing.
the leakage check ② Damage of the O Ring of paint pipe/plug ② Replace the O Ring of paint pipe/plug.
hole of the gun.
5. Unstable opening/ ① Wear-out of the O Rings around the ① Replace the O Rings around the piston.
closing of trigger piston.
valve ② Wear-out of piston spring ② Replace the piston spring.

30
 Symptom Cause Countermeasure
6. Spark is discharged ① Damage of power pack ① Replace the power pack.
from nozzle. (When
the insulating stand
is not used)
7. Spark is discharged ① Damage of power pack ① Replace the power pack.
from nozzle. (When ② Paint is changed to the one with a low ② Lower the output voltage of the static
the insulating stand electric resistance value or to a metallic electricity controller.
is used) paint.
8. Warning buzzer of the ① Paint is affixed on the exterior of the gun. ① Clean the exterior of the gun.
control unit goes off. ② Paint is affixed in the inner diameter of ② Clean the paint hose.
(When the insulating the paint hose.
stand is not used) ③ Moisture is accumulated in the air line. ③ Drain water from the air line thoroughly.
Turn off the static electricity controller and
open the trigger valve to perform air
purge to discharge water from the air line.
④ Paint is changed to the one with a low ④ Use the insulating stand.
electric resistance value or to a metallic
paint.
⑤ Paint is leaked due to damage of the ⑤ Replace the bellows needle.
bellows seal.

9. Warning buzzer of ① Paint is affixed on the exterior of the gun. ① Clean the exterior of the gun.
the control unit ② Paint is affixed in the inner diameter of ② Clean the paint hose.
goes off. (When the the paint hose.
insulating stand is ③ Moisture is accumulated in the air line. ③ Drain water from the air line thoroughly.
used) Turn off the static electricity controller and
open the trigger valve to perform air
purge to discharge water from the air line.
④ There is a grounding object near the ④ Place the insulating stand 300 mm or
insulating stand. more away from the grounding object.
⑤ Paint is affixed to the insulating bar of the ⑤ Clean the insulating bar.
insulating stand.
⑥ The section above the insulating bar of ⑥ Separate the grounded section above the
the insulating stand is grounded. insulating bar.
⑦ Paint is leaked due to damage of the ⑦ Replace the bellows needle.
bellows seal.

CAUTION
Do not make repairs with any methods other than
those specified in this instruction manual.

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9
9.1
How to Replace Parts
Disassembly of Gun Body (Refer to Art.10, “Parts List”)

(1) Removal from Gun Bracket

１．First, after confirming that there is no pressure in paint and air lines,
remove Shroud (1832-004) by turning it with hand.
２．Remove two Bolts, M4×15, 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 paint will be
pushed out from Paint Hose and sticks to inside of the Gun, through which electrostatic
will leak causing over current and, then, impossibility of electrostatic coating.

(2) Disassembly of Paint Valve

１．Remove two plastic Bolts, M8×30, (364-0030) from Gun Head.
２．Pull out Gun Head (1832-001).
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 (1728) at Gun’s front
head using plain driver.
５．After removing Paint Seat, insert a Hex. wrench (3mm) into hole where the Seat was, to push out
Seal Collar (1832-009).
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.
(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 (1832-008), 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.

32
 (4) Cleaning of paint passage in Gun Head
１．Remove Plugs (131E-002, 131F-002) at two points in the Head (1832-001) and remove paint
sticking to inside of it.

NOTE
There are three Plug 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 valve air

(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

9.2 Replacement 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.

33
 (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.

9.3 Replacement of Connecting Cable →Refer to Art.9 “How to Replace Parts”

9.4 Installing Orifice

An orifice can be mounted on the gun as a part to adjust the discharge amount.

(1) Insert an orifice to the specified location as the Paint Nozzle Assy and charge electrode are removed.

1728: Paint Seat

Orifice Orifice

(2) Install the Paint Nozzle Assy with the charge electrode mounted as being careful not to drop the
installed orifice.

(3) While a φ0.7 orifice (Part No.: 1832-750) is included in the component parts as an accessory part, select
an appropriate orifice, which is sold separately, in the table below according to the usage.
Diameter of orifice Parts No. How to identify Remarks

φ0.5 1832-550

Number of identification
lines = 1

φ0.7 1832-750 Initial component part

Number of identification
lines = 3

φ0.9 1832-950

Number of identification
lines = 5

34
10
10.1 EAB400
Exploded Diagram and Names of Parts

EAB400
EAB400
4
１８３２

12
13
33
11
8
10
1 38 9
22
29
26
21
37
18
20
16 31
19
35

26 35
15
14 24
17 23
5 30 27 32
7 28 25
6
3
36 32
30 27

34

2
Part name Part No Q’ty Remark Part name Part No Q’ty Remark

1 1832-001 Head 1 21 1728 Paint Seat 1

2 137F-002 Body 1 22 137F-025 Packing 1
3 1285-042 Spring 1 23 137F-030 Joint 1
4 1832-004 Shroud 1 24 137F-032 Plug 1
5 1832-005 Bracket 1 25 137F-034 Gasket 1
6 137F-006 Connector 1 26 364-0030 Hex Socket Screw 2 M8×20L

7 145F-007 Cascade 1 27 03-70520 Hex Socket Screw 2 M5×20L

8 1832-008 Needle 1 28 12-10204 Sems Screw 2P 3 M2×4L

9 1832-009 Seal collar 1 29 15-70300 Hex nut 1 M3

10 6008-007 Screw 1 30 376-0802 Quick Joint 2
11 6008-008 Piston 1 31 101-9004 O Ring 1 P4
12 137F-012 Cap １ 32 101-9007 O Ring 2 P7
13 0721-020 Spring 1 33 101-9014 O Ring 1 P14
14 131E-002 Plug 2 34 102-9065 O Ring 1 G65
15 131F-002 Plug 1 35 130-9004 O Ring 4 S4
16 15F7 Paint Nozzle Assy 1 36 130-9010 O Ring 2 S10
17 364-0019 Cross Recessed Pan Screw 1 37 130-9042 O Ring 1 S42
18 152-0004 U packing 2 P4 38 101-9008 O Ring 2 P8
19 1707 Retaining nut Assy 1 39 1719 Parts set 1
20 1718 Charge Electrode 1 40 35EE Tool set 1

35
ＥＡＢ４００
１８３２-１

12
33 13
11
22 10 8
38 9
1
29
26 21
37
18
20 31
16
19
35
26 35
15

14 30 30

17 27
23
5
7
28
25 24
3
36 6

32

27

32

34
2

番号 部品番号 品 名 個数 備考 番号 部品番号 品 名 個数 備考
1 1832-001 Head 1 21 1728 Paint Seat 1
2 137F-002 Body 1 22 137F-025 Packing 1
3 1285-042 Spring 1 23 137F-030 Joint 1
4 1832-004 Shroud 1 24 137F-032 Plug 1
5 1832-105 Bracket 1 25 137F-034 Gasket 1
6 137F-006 Connector 1 26 364-0030 Hex Socket Screw 2 M8×20L

7 145F-007 Cascade 1 27 03-70520 Hex Socket Screw 2 M5×20L

8 1832-008 Needle 1 28 12-10204 Sems Screw 2P 3 M2×4L

9 1832-009 Seal collar 1 29 15-70300 Hex nut 1 M3

10 6008-007 Screw 1 30 376-0802 Quick Joint 2
11 6008-008 Piston 1 31 101-9004 O Ring 1 P4
12 137F-012 Cap １ 32 101-9007 O Ring 2 P7
13 0721-020 Spring 1 33 101-9014 O Ring 1 P14
14 131E-002 Plug 2 34 102-9065 O Ring 1 G65
15 131F-002 Plug 1 35 130-9004 O Ring 4 S4
16 15F7 Paint Nozzle Assy 1 36 130-9010 O Ring 2 S10
17 364-0019 Cross Recessed Pan Screw 1 37 130-9042 O Ring 1 S42
18 152-0004 U packing 2 P4 38 101-9008 O Ring 2 P8
19 1707 Retaining nut Assy 1 39 1719 Parts set 1
20 1718 Charge Electrode 1 40 35EE Tool set 1

36
10.2 Replacement Parts

The replaceable parts in the part ASSY are shown below.

Regarding the parts that are not shown below, replace the Assy.

Paint Nozzle Assy Retaining nut Assy

15F7 1707
130-9012
:O RING

373-0010
: Ring Seal

When Ring seal is removed from Retaining nut,

Please replace to new one

Paint Seat Parts Set

1728 1728-001 1719

: Paint Seat
1724-002 1832-750
: Plug :φ0.7 Orifice
※Paint circulation type ※To adjust paint flow

130-9006
:O RING
101-9005
:O RING

130-9004
Tool Set :O RING

35EE

35CF-001 333-1075
: Plate Spanner : Flathead screwdriver
※For Paint Nozzle ※For Paint Seat

37
11
789+e Maintenance Log

Shown below is a maintenance log format of a kind we recommend you to keep. Each time that you conduct a
maintenance service, such as replacement of a part, tear-down cleaning, post-failure repair, etc., record the
details. In the long run, you will find that such a log is very valuable in keeping your equipment in a
consistently good operating condition.

Equipment Automatic electrostatic air spray gun: Date of purchase:

name Robogun III <EAB400>
Date of service Portion worked on Description Results Who serviced
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
In-house / Agency /
Asahi Sunac
NOTE: Due to continuous improvements and modifications, the configurations and specifications of the
equipment specified herein are subject to change without prior notice.

38
12 Warranty

ASAHI SUNAC CORPORATION (the “Company”) shall provide the original purchaser (the “Purchaser”)
with warranty service for a period of one (1) year from the date of purchase of the product, as follows:

● Should you find defects in design or workmanship with regard to parts, ship them back to the Company,
with freight prepaid. The Company shall repair or replace the parts free of charge and reimburse the
freight charges, provided that, as a result of an inspection and investigation of the parts conducted by the
Company, the defects are deemed to be to attributable to the factors within the Company’s responsibility.

● In the following cases, free after-sales service is not provided.

1. Failure resulting from an inappropriate method of installing this equipment.

2. Failure resulting from a use method not conforming to this instruction manual or mishandling.
3. Failure resulting from insufficient maintenance management of this equipment and incorrect
handling such as non-conformance to the procedures specified in this instruction manual.
4. Failure resulting from unauthorized alteration or structure change of this equipment without the
Company’s consent.
5. Failure due to force majeure such as earthquake, disaster, flood disaster or lightening.
6. Warranty for consumables worn or deteriorated even in the case where this equipment is used
correctly.
7. Repair after the machine has been used outside Japan, and shipping cost.
8. In addition to the above, failure due to circumstances beyond our control.

● As for items such as parts purchased by the Company from another manufacturer, the warranty of that
manufacturer shall apply.

● As for any parts deemed to be defective, the Company shall not be held liable for any expenses beyond
the provision of repair or replacement parts free of charge.

● The Company shall not be held liable for any damage to the Purchaser caused by factors not
attributable to the Company, such as misuse of product, etc.

39
●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.

7th edition: September 3, 2018

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

40