Danger Caution Danger of Life Do not attempt to perform service on a hot heat gun. Always allow unit to cool completely and disconnect from power source before performing any service on the heat gun. Fire and Explosion Hazard Can be caused by an incorrect use of the hot air gun, especially near combustible materials and explosive gases. Danger of Burns! Do not touch the element housing and nozzle when HOT, let the tool cool down. Do not point the hot air flow in the direction of people or animals. The voltage rating stated on the tool must correspond to the line/ mains voltage. Protect the tool from moisture and wetness. Tools Required For Servicing: Needle Nose Pliers Tweezers T-10 Torx Screw Driver T-20 Torx Screw Driver Pocket Screw Driver Compressed Air (Recommended) Disclaimer: The information contained here is accurate and reliable to the best of our knowledge at time of printing and is subject to change without notice. No responsibility is assumed by Hapco, Inc. for use of this information. Hapco, Inc. and its logo are trademarks of Hapco, Inc. All other trademarks are the property of their respective companies. 2013 Hapco, Inc. All rights reserved. 1
BAK RiOn Tune-Up Kit Table of Contents Please read all instructions prior to disassembling heat gun. If performing a complete tune-up on heat gun, it is suggested that you adhere to the following sequence of steps: CHAPTER DESCRIPTION PAGE 1 Replacing the Heating Element & Mica Tube 3 2 Replacing the Brushes and Springs 6 3 Replacing the Power Cord 11 4 Replacing the Air Intake Filter 16 5 RiOn Complete Parts List 17 6 RiOn Exploded Parts Diagram 18 Technical Support If you have technical questions or are experiencing problems with your RiOn Tune-Up Kit, please call our FREE technical support line: 1-800-345-9353 Open Monday - Friday 8:00am-4:30pm EST Closed Major Holidays Or Call Us For An Authorized Repair Center Near You! 2
Chapter 1 Replacing the Heating Element & Mica Tube DO NOT ATTEMPT TO PERFORM SERVICE ON A HOT TOOL. ALWAYS ALLOW UNIT TO COOL COMPLETELY AND DISCONNECT FROM POWER SOURCE BEFORE PER- FORMING ANY SERVICE ON THE HEAT GUN. STEP 1 Remove the 4 T-20 screws from the base of the metal heater tube by using a T-20 Torx screw driver. STEP 2 Slide metal heater tube off of RiOn by gently pulling outward. Metal heater tube should easily slide away from the heating element and mica tube. STEP 3 Slide mica tube and element gasket off heating element. Discard mica tube and put gasket aside for re-assembly. 3
Chapter 1 - Cont. Replacing the Heating Element & Mica Tube STEP 4 Remove the heating element by grasping at base of heating element and pulling outward. You will feel some resistance as the heating element plugs into 2 sockets. STEP 5 Replace new heating element by lining up both metal prongs on heating element with both socket holes on the heat gun. Press heating element firmly into sockets ensuring you have good contact. STEP 6 Install new mica tube by sliding it over the new heating element. The mica tube is required for proper heating and cooling of the unit. (Your repair kit may have the mica tube already covering the heating element). 4
Chapter 1 - Cont. Replacing the Heating Element & Mica Tube STEP 7 Replace the felt gasket by sliding it over the mica tube and heating element. Ensure the gasket is snug against the face of the heat gun. NOTE: Place the gasket around the mica tube with orange side facing outward. STEP 8 Replace the metal heating tube by sliding it over the mica tube and aligning the 4 screw holes on the metal heating tube with the 4 holes on the face of the heat gun. STEP 9 Replace all 4 screws using a T-20 Torx screw driver. Tighten all screw until they are snug. Pay attention not to over tighten screws as they will strip the threads in the screw holes. 5
Chapter 2 Replacing the Brushes & Brush Springs DO NOT ATTEMPT TO PERFORM SERVICE ON A HOT TOOL. ALWAYS ALLOW UNIT TO COOL COMPLETELY AND DISCONNECT FROM POWER SOURCE BEFORE PER- FORMING ANY SERVICE ON THE HEAT GUN. STEP 1 Remove rubber ring stand from the body of the RiOn heat gun. The rubber ring stand sits within an inner groove and needs to be stretched over the groove to remove from the body of the heat gun. STEP 2 Remove the three outer screws located on the GREEN body using a T-20 Torx screw driver. STEP 3 Firmly grasp the heat gun and gently pull apart pulling the metal heating tube away from the body of the heat gun. 6
Chapter 2 - Cont. Replacing the Brushes & Brush Springs STEP 4 Depending on the condition of the heat gun, use compressed air to blow out entire internal components of the heat gun. STEP 5 Locate brush and metal quick release wire connector. Using a pocket screw driver or needle nose pliers, remove connector by prying it off the metal terminal. STEP 6 Locate brush spring holding the brush in place. Using a pocket screw driver, lift the spring leg off of the brush and guide it to the side of the brush so that it is resting against the plastic housing. Use care as spring is under tension and will jump out of place if not properly held in place. 7
Chapter 2 - Cont. Replacing the Brushes & Brush Springs STEP 7 Pull the brush out of the housing by pulling on the bare metal wire connected to the brush. Discard the old worn brush. STEP 8 Inspect the spring. If the spring is not rusted, broke or bent, it is recommended not to replace the spring. However, if you do see signs of wear, using tweezers, grab a hold of the spring and remove from the spring stand. STEP 9 Replace new brush by placing it back into the socket with groove on top of the brush facing the back side of the heat gun. 8
Chapter 2 - Cont. Replacing the Brushes & Brush Springs STEP 10 Using tweezers, install new spring by setting it in the spring stand. Loop the long end of the spring up and around bringing it to the top of the brush. Ensure the spring leg is resting in the groove on the top of the brush. Use care as spring will be under tension and will be difficult to put in place. STEP 11 Using needle nose pliers, re-connect the quick connect wire from the end of the brush by sliding it back on to the metal connector prong.sstep 13 STEP 12 Repeat steps 5-11 for the second brush and spring. IF YOU INTEND TO REPLACE THE POWER CORD, PROCEED TO STEP 5 IN CHAPTER 3 (PG. 12). 9
Chapter 2 - Cont. Replacing the Brushes & Brush Springs Close heat gun by guiding metal heating tube towards the body of the heat gun while lining up the three screw holes. Insert and tighten screws until they are snug. Do not over tighten screw as you will strip the plastic threads. STEP 14 Replace rubber ring stand around the heat gun. Ensure the rubber lip fits tightly into the channel around the body of the heat gun. 10
Chapter 3 Replacing the Power Cord DO NOT ATTEMPT TO PERFORM SERVICE ON A HOT TOOL. ALWAYS ALLOW UNIT TO COOL COMPLETELY AND DISCONNECT FROM POWER SOURCE BEFORE PER- FORMING ANY SERVICE ON THE HEAT GUN. STEP 1 Remove rubber ring stand from the body of the RiOn heat gun. The rubber ring stand sits within an inner groove and needs to be stretched over the groove to remove from the body of the heat gun. STEP 2 Remove the 3 outer screws located on the GREEN body using a T-20 Torx screw driver. STEP 3 Firmly grasp the heat gun and gently pull apart pulling the metal heating tube away from the body of the heat gun. 11
Chapter 3 - Cont. Replacing the Power Cord STEP 4 Depending on the condition of the heat gun, use compressed air to blow out entire internal components of the heat gun. Always direct air flow away from the heat nozzle and towards the rear of the heat gun. STEP 5 Locate the black plastic strain relief cap near the end of the power cord. Loosen both screws using a T-10 Torx screw driver. STEP 6 Using a T-20 Torx screw driver, loosen but do not remove two power contact screws (white & black wires). 12
Chapter 3 - Cont. Replacing the Power Cord STEP 7 Lift power cord from rear housing and gently pull wires out from under the two power contact screws. Once power cord is separated from heat gun, remove cord guard from the end of the power cord. STEP 8 Slide the power cord out of the rear of the heat gun. STEP 9 Replace new cord by sliding it through the rear of the heat gun and then replace the cord guard on the end of the power cord. 13
Chapter 3 - Cont. Replacing the Power Cord STEP 10 Separate the white and black wires to create a Y shape. Slide both wires underneath the torsional protection washers and placed on outer edges of contact screws. NOTE: The white and black wires can be placed under either power contact screw but normally the white wire is connected to the right screw. STEP 11 Tighten both power contact screws using a T-20 Torx screw driver. Be careful not to over tighten screws. Slightly twist power cord to tighten slack near the power contact screws. STEP 12 Tuck cord guard back into the slot located on the rear of heat gun housing. Realign strain relief over power cord and screw on to housing using a T-10 Torx screw driver. As you tighten screws, be sure strain relief is overlapping black shrouding and not touching the black or white wires. 14
Chapter 3 - Cont. Replacing the Power Cord STEP 13 Replace the green housing while sliding the power cord through the rear of the heat gun. STEP 14 Re-align screw holes on body and screw together using a T-20 Torx screw driver. STEP 15 Replace rubber ring stand around the heat gun. Ensure the rubber lip fits tightly into the channel around the body of the heat gun. 15
Chapter 4 Replacing the Air Intake Filter DO NOT ATTEMPT TO PERFORM SERVICE ON A HOT TOOL. ALWAYS ALLOW UNIT TO COOL COMPLETELY AND DISCONNECT FROM POWER SOURCE BEFORE PER- FORMING ANY SERVICE ON THE HEAT GUN. STEP 1 Using a small pocket screw driver, wedge the blade of the screw driver underneath the plastic filter near the opening of the power cord and pry filter upwards. The plastic filter should un-snap from the heat gun. STEP 2 Depending on the condition of the filter, use compressed air to blow out filter and the air intake area of the heat gun. In some cases, the filter will need to be replaced. STEP 3 Replace new filter with molded numbers on the filter facing outward. Press into place starting at bottom (open end) of filter and slowly press downward as you move up the edge of the filter. The new filter should snap into place. 16
Chapter 5 Complete RiOn Parts Listing 17
Chapter 6 Complete RiOn Parts Diagram 18