Binks 104085 Service Manual Download Page 1

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Electric Drive Pump

Service Manual

E2-60

• 104085 (EU Model)
• 104086 (USA Model)
• 104087 (Japan Model)

77-3228 R3.3

www.carlisleft.com

Summary of Contents for 104085

Page 1: ...EN Electric Drive Pump Service Manual E2 60 104085 EU Model 104086 USA Model 104087 Japan Model 77 3228 R3 3 www carlisleft com ...

Page 2: ...irements EN 1127 1 2011 Explosive atmospheres Explosion prevention Basic concepts EN 13463 1 2009 Non electrical equipment for use in potentially explosive atmospheres Basic methods and requirements EN 13463 5 2011 Non electrical equipment for use in potentially explosive atmospheres Protection by constructional safety c EN 13463 8 2003 Non electrical equipment for potentially explosive atmosphere...

Page 3: ...F THE EQUIPMENT HIGH PRESSURE CONSIDERATION High pressure can cause serious injury Relieve all pressure before servicing Spray from the gun hose leaks or ruptured components can inject fluid into your body and cause extremely serious injury KEEP EQUIPMENT GUARDS IN PLACE Do not operate the equipment if the safety devices have been removed STATIC CHARGE Fluid may develop a static charge that must b...

Page 4: ...4 7 basis NOTE Gearbox Oil EU Model Synthetic 220 typically Agip Blasia S Gearbox Oil USA Model 1 50 l m 0 40 US gal m EN SPECIFICATION Nominal pump stroke 50mm 1 97 ins 20 bar 290psi 3 0 kW 4Pole 1400 RPM EEx d 11B T3 295kg 650lbs E2 60 Nominal flow volume cycle E2 60 Maximum fluid pressure 1 Sanitary 1 Sanitary SHC 630 Synthetic Oil Pressure when used in Smart Mode Closed Loop Pressure Mode AC I...

Page 5: ...ND MOUNTING DETAILS M6 HEX Head screw for pump earth grounding the Pump Frame must be wired to a suitable earth ground to ensure that there is no possibility of static build up B A 77 3228 R3 3 5 36 www carlisleft com ...

Page 6: ...sure switch and or Pressure relief valve must be connected to the outlet manifold port and set to stop the pump or relieve the fluid pressure in the event of the system overpressure The Pressure Switch should be wired as a Normally Closed contact fail safe and be hard wired to stop the motor on operation to minimise response time The Pressure Switch is classified as simple apparatus and as such sh...

Page 7: ...s The motor is fitted with PTC temperature sensors Thermistors Value Maximum Hz Output 80 Hz Mininmum Hz Output 20 Hz Acceleration Ramp Deceleration Ramp Rated Motor Power 3 0 kW Inverter Required Inverter Settings Rated Motor Current Rated Motor Voltage 400 V Rated Motor Speed 1440 RPM INSTALLATION Electric Motor Once operating temperature is reached this device quickly changes the resistance If ...

Page 8: ...lug is supplied in a bag attached to the gearbox Check that the oil plug on top of Gearbox has been replaced with the correct venting plug Ensure adequate air space around the Pump for maintenance and electric motor cooling requirements Attach suitable flexible hoses to the inlet and outlet connections Outlet Ø32 38 I D 20 bar working pressure 77 3228 R3 3 8 36 www carlisleft com ...

Page 9: ...Set the pump speed to the minimum frequency 20 Hz and start the pump to remove any air from the circuit Inspect for any system leaks Set the pump cycle rate to achieve the required paint volume and then adjust the system back pressure regulator to achieve the desired system fluid pressure Smart Mode The return line back pressure regulator responds to the changes in system fluid flow demand due to ...

Page 10: ...69 ATEX GEARBOX 1 EU MODEL REMARKS 2 1 QTY EU MODEL 192684 3 0KW ATEX MOTOR 1 4 DESCRIPTION PART NUMBER ITEM 194903 1 193710 1 1 193456 2 2 192685 USA MODEL 4 COVER C W CAP FIXINGS 2 165077 5 7 164469 1 JAPAN MODEL 4 192819 2 USA MODEL 3 192864 11 E2 60 MECHANICAL ASSY M12 WASHER M14 SPRING WASHER ST ST M12 SPRING WASHER ST ST M12 x 40 CAP HEAD SCREW M14 x 40 CAP HEAD SCREW 77 3228 R3 3 10 36 www ...

Page 11: ...EN Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3228 R3 3 11 36 www carlisleft com ...

Page 12: ...D 1 5 193747 INLET MANIFOLD SANITARY CLAMP 192009 10 192008 1 5 SANITARY GASKET 1 5 PRESSURE RELIEF VALVE 1 104168 1 2 7 194591 8 194593 1 1 193746 3 1 1 1 5 ELBOW 1 5 ELBOW 1 5 ELBOW KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3228 R3 3 12 36 www carlisleft com ...

Page 13: ...ME 2 22 192650 GREASE NIPPLE 2 23 192654 1 24 192661 PUSH IN ELBOW 2 25 192662 2 26 192870 GREASE BULKHEAD 2 27 193131 PUSH IN ELBOW 2 M8 SPRING WASHER M16 SPRING WASHER M16 WASHER M12 WASHER M8 NYLOC NUT M12 SPRING WASHER M8 MUD GUARD WASHER STST M6 WASHER BRASS Ø6 GREASE HOSE Ø8 WASHER Ø10 SPRING WASHER M12 x 40 HEX HEAD CAP SCREW M10 x 40 CAP HEAD SCREW M10 x 20 GRUB SCREW M16 x 30 CAP HEAD SCR...

Page 14: ...1 2 193449 193455 33 2 29 4 193434 1 38 194541 4 BELL HOUSING CAM ASSY Parts list continued 28 193430 MAIN BODY MACHINING 1 CARRIAGE SPRING LINEAR BEARING ROD 32 193454 LEAK DETECTION HOSE ASSY 2 CARRIAGE ASSEMBLY SHAFT CLAMP ASSY ITEM PART NUMBER DESCRIPTION QTY REMARKS Ø50 COUPLING SPACER 77 3228 R3 3 14 36 www carlisleft com ...

Page 15: ...EN Tighten bolts holding carriage ends once pump is fully assembled KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3228 R3 3 15 36 www carlisleft com ...

Page 16: ...ghtened using tool 502509 Part No 6 To be pressed into housing using tool 502511 Part No 5 To be pressed into housing using tool 502510 NOTE KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3228 R3 3 16 36 www carlisleft com ...

Page 17: ...CRIPTION QTY REMARKS 1 w 1 163951 6 2 163952 6 3 192616 TOP BEARING CAP 1 1 w 4 192617 BOTTOM BEARING CAP 1 5 192639 7 192644 1 w 8 192650 GREASE NIPPLE 1 9 192655 1 10 192656 1 6 192640 11 193431 BELL HOUSING MACHINING 1 M50 BEARING LOCKNUT M45 BEARING LOCKNUT M6 x 20 CAP HEAD SCREW M6 x 16 CAP HEAD SCREW 77 3228 R3 3 17 36 www carlisleft com ...

Page 18: ...RKS 193435 193436 SHAFT ASSEMBLY 1 13 CONSTANT VELOCITY CAM 193440 1 15 Parts list continued 165571 10 14 16 1 BOTTOM SHAFT 1 17 BOTTOM BEARING HOUSING 1 193437 12 M10 x 70 CAP HEAD SCREW 194511 TOP SHAFT 77 3228 R3 3 18 36 www carlisleft com ...

Page 19: ... FOLLOWER PIN CARRIAGE CENTRE CAM FOLLOWER x SPACER CARRIAGE ADAPTOR LINEAR BEARING 6 4 2 1 1 ITEM PART NUMBER 192651 192661 193103 193438 193441 DESCRIPTION x x CARRIAGE END CIRCLIP 6 177012 2 GREASE NIPPLE 7 192649 2 M10 x 25 CAP HEAD SCREW M20 NYLOC NUT M20 SPRING WASHER M10 SPRING WASHER FOLLOWER NUT WASHER 165123 165139 165947 166158 177011 193439 12 77 3228 R3 3 19 36 www carlisleft com ...

Page 20: ...EN KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3228 R3 3 20 36 www carlisleft com ...

Page 21: ...LY 1 8 8 uv 2 4 1 1 1 1 v 160513 164472 165077 165108 171788 192551 192595 192626 192505 8 OUTLET CAGE OUTLET CHECK HEXAGON PLUG 11 SPRING 177032 6 9 10 192632 193651 13 16 17 18 20 ITEM PART NUMBER DESCRIPTION QTY REMARKS 1 2 3 4 5 M14 x 45 CAP HEAD SCREW M14 x 45 CAP HEAD SCREW 1 3 8 BALL M8 SPRING WASHER M14 SPRING WASHER M8 x 25 SCREW Ø41 X 1 78 O RING Ø50 5 X 2 62 O RING Ø12 42 X 1 78 O RING ...

Page 22: ...EN KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3228 R3 3 22 36 www carlisleft com ...

Page 23: ...RIPTION QTY REMARKS 1 uv uv 4 162807 162806 3 BALL CAGE 1 9 193653 192629 6 SEAT 1 v v 5 uv 1 162805 2 Use a 36mm Single Hex Socket when tightening or removing ball cage from Piston Ø50 52 X 1 78 O RING Ø107 62 X 2 62 O RING Ø63 17 X 2 62 O RING KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3228 R3 3 23 36 www carlisleft com ...

Page 24: ...ONING TOOL ITEM PART NUMBER DESCRIPTION QTY REMARKS 3 4 5 Smear loctite 572 over nose of bellows thread nut onto bellows ensuring the thread starts squarely Grip bellows lightly by hand and tighten the nut with a 1 A F spanner until the nut contacts the bellows shoulder Screw Item No 6 assembly spigot onto the piston shaft grease spigot with AMGD 010 KEY Reverse for assembly LOCTITE TORQUE MAINTEN...

Page 25: ...re parts kits NOTE Before any maintenance always switch off the pump and secure against any unintentional start up The two components which are more greatly affected by the above criteria than any other components in the pump are Maintenance General Maintenance The working life and thus the expected life prior to replacement of parts within a Paint Pump are greatly affected by three main factors 7...

Page 26: ... Every 5 Years Replace main shaft bearings Linear Guide Bearings Guide Rails and Cams if excessive wear can be seen Use only 502375 KP2N 20 DIN 51825 Grease for Cam Follower Bearing Maintenance Maintenance schedule Inspection Operation Daily Check for any fluid leakage 3 Monthly While running apply 502375 grease to cam follower bearings 8 strokes of a standard cartridge grease gun 502373 6 Monthly...

Page 27: ...d to be drained maintained and filled with oil Note Maintenance Gearbox WARNING Wait until the unit has cooled sufficiently after stopping and isolation Gearbox Every 1000 hours verify the good condition of oil seals and gaskets General overhauls must only be done by authorised certified service personnel or companies It is recommended that the oil should be warm 40 50º C to facilitate easier drai...

Page 28: ...nductors required by the standards must be respected The electric connections must be correctly locked to avoid resistance increases with consequent contact overheating Maintenance Motor For the Ex motors the repairs of parts directly involved on the protection against the explosion risk must be done without any modification to the original motor design WARNING Wait until the unit has cooled suffi...

Page 29: ...n Grease bearing or replace if damage is too great Bearing needs lubrication Cam Followers bearing generating heat noise Remedy Possible Cause Symptom a Defective gasket on gear unit cover from the output oil seal from the gear unit flange from the motor flange from the gear unit cover b Fluid seal friction or piston movement prevented a Spring tension insufficient b Fluid seal friction or piston ...

Page 30: ...ower worn b Main shaft bearings worn a Ball checks not seating correctly b Inspect clean and or replace balls and seats a Replace piston seals b Inverter Unit or safety interlocks tripped a Worn piston seals b Inverter Unit or safety interlocks tripped a No power b Check inverter and fault conditions a Check electrical supply c Inspect clean and or replace balls and seats b Replace piston seals a ...

Page 31: ...r to a suitable electrical supply 8 9 Fluid Drain Down The pump will now have most of the paint removed IMPORTANT Check for any leaks and mechanical noises Run the pump at 20 cycles min 50 HZ and increase the back pressure to 10 bar and run for 1 hour Never allow the pump to run with a closed valved off inlet or outlet connection While running apply 502375 grease to main shaft bearing 40 strokes o...

Page 32: ...ps FLUID SECTION SEAL KIT 250632 FLUID SECTION OVERHAUL KIT 250687 MAIN BEARING OVERHAUL KIT 250683 LINEAR BEARING 193448 Spare Parts List BELLOWS FLUID SECTION 193451 CAM FOLLOWER BEARING LINEAR GUIDE AND ROD KIT 250684 CAM FOLLOWER BEARING KIT 250685 Check Main Parts List for details of Individual Kit Contents 77 3228 R3 3 32 36 www carlisleft com ...

Page 33: ...02376 SENSOR MANIFOLD SMART CARD BPR CONTROL BOX 502501 192547 502483 ELECTRICAL PANEL FOR SINGLE PUMP OPERATION INC SMART CARD COLLET CONNECTOR GREASE GUN FOR CAM FOLLOWER MAIN BEARINGS 502373 502514 HOOK CONNECTOR GREASE GUN FOR LINEAR BEARINGS 300mm EXTENSION GREASE FOR CAM FOLLOWER MAIN BEARINGS PRESSURE FEEDBACK 192008 192009 77 3228 R3 3 33 36 www carlisleft com ...

Page 34: ...SECURITY SCREWDRIVER FOR COVER TOP BEARING PRESS TOOL 502510 502511 BOTTOM BEARING PRESS TOOL SHAFT ASSEMBLY TOOL BELLOWS ASSEMBLY TOOL BELLOWS ASSEMBLY SPIGOT 192450 PART NUMBER DESCRIPTION REMARKS 502512 502681 502682 FOC with a New Pump TOP BEARING LOCKNUT TOOL 502508 77 3228 R3 3 34 36 www carlisleft com ...

Page 35: ...EN NOTES 77 3228 R3 3 35 36 www carlisleft com ...

Page 36: ...dify equipment specifications without prior notice DeVilbiss Ransburg MS BGK and Binks are registered trademarks of Carlisle Fluid Technologies Inc 2018 Carlisle Fluid Technologies Inc All rights reserved Binks is part of Carlisle Fluid Technologies a global leader in innovative finishing technologies For technical assistance or to locate an authorized distributer contact one of our international ...

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