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Carlisle Fluid Technologies 107071, Service Manual

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Carlisle Fluid Technologies 107071 Service Manual Download Page 8

EN

 

 

 

 

 

 

(The gearbox is filled with the correct amount of oil at the factory) 

Ensure the gearbox is filled with oil.

Ø50 I.D. [-1 to 10 bar working pressure]

Outlet - Ø38 - 50 I.D. [20 bar working pressure]

Ensure adequate air space around the Pump for maintenance and electric motor cooling requirements.

Check that the oil plug on top of Gearbox has been replaced with the correct venting plug.

INSTALLATION

Attach suitable flexible hoses to the inlet and outlet connections.
e.g.,

Suction - 

The vent plug is supplied in a bag attached to the gearbox.

77-3215 R5.5

8/40

www.carlisleft.com

Summary of Contents for 107071

Page 1: ...del 107093 EU Model IMPORTANT DO NOT DESTROY It is the Customer s responsibility to have all operators and service personnel read and understand this manual Contact your local Carlisle Fluid Technologies representative for additional copies of this manual READ ALL INSTRUCTIONS BEFORE OPERATING THIS PRODUCT 77 3215 R5 5 1 40 www carlisleft com ...

Page 2: ...ospheres Equipment General requirements EN 60079 1 2014 Explosive atmospheres Equipment protection by flameproof enclosures d EN 60079 7 2015 Explosive atmospheres Equipment protection by increased safety e EN 60034 1 2010 Rotating electrical machines Providing all conditions of safe use installation stated within the product manuals have been complied with and also installed in accordance with an...

Page 3: ...isuse can cause the equipment to rupture malfunction or start unexpectedly and result in serious injury PACEMAKER WARNING You are in the presence of magnetic fields which may interfere with the operation of certain pacemakers WARNING Read the following warnings before using this equipment READ THE MANUAL Before operating finishing equipment read and understand all safety operation and maintenance ...

Page 4: ...2 30 Fluid Output 80 HZ 40 cycles min E2 40 Fluid Output 80 HZ 40 cycles min 1 Sanitary Nominal pump stroke 50mm 1 97 ins 20 7 bar 300psi EN 16 bar 232psi SPECIFICATION E2 30 Maximum fluid pressure E2 40 Maximum fluid pressure E2 30 Nominal flow volume cycle 0 75 l m 0 20 US gal m AC Induction Electric Motor USA Model 460V 3PH 1 Hp 60HZ Class 1 Group D Total Weight of Pump inc electric motor 250 k...

Page 5: ...me must be wired to a suitable earth ground to ensure that there is no possibility of static build up DIMENSIONS AND MOUNTING DETAILS M6 HEX Head screw for pump earth grounding B A 77 3215 R5 5 5 40 www carlisleft com ...

Page 6: ...e the maximum required pressure The Pressure Switch is classified as simple apparatus and as such should be electrically connected as part of an intrinsically safe electrical circuit 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 INSTALLATION The Pump Units are designed for location in Zone 1 Haz...

Page 7: ...d be in doubt it must be connected to a suitable releasing device mounted within the control panel and wired to stop the motor if an over temperature occurs Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into consideration Only trained personnel familiar with these standards should handle this type of apparatus Required Inverter Settings 5 Sec...

Page 8: ...essure Ensure adequate air space around the Pump for maintenance and electric motor cooling requirements Check that the oil plug on top of Gearbox has been replaced with the correct venting plug INSTALLATION Attach suitable flexible hoses to the inlet and outlet connections e g Suction The vent plug is supplied in a bag attached to the gearbox 77 3215 R5 5 8 40 www carlisleft com ...

Page 9: ...g the set pressure Ensure all electrical and mechanical connections are correctly made All required interlocks are tested and operational Suitable material for pumping is available at the suction hose The outlet connection is not blocked or isolated by any valves Check the gearbox oil level please note the the gearbox is supplied with life lubricant and does not need any maintenance Set the pump s...

Page 10: ...4 8 8 192666 1 5KW ATEX MOTOR 3 M12 x 40 CAP HEAD SCREW E2 30 FLUID SECTION E2 40 FLUID SECTION 1 EU MODEL Not Shown USA MODEL 1 192667 1 5KW ELECTRIC MOTOR 192669 H063 GEARBOX H063 GEARBOX M12 HEXAGON NUT M12 WASHER 1 EU MODEL PARTS LIST Pump Assembly 192756 1 JAPAN MODEL Not Shown 192670 1 USA MODEL Not Shown 2 5 164470 4 192755 ITEM PART NUMBER DESCRIPTION QTY REMARKS 1 193709 1 77 3215 R5 5 10...

Page 11: ...EN KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3215 R5 5 11 40 www carlisleft com ...

Page 12: ...EXT SANITARY ELBOW E2 40 1 5 119mm EXT SANITARY ELBOW E2 30 1 5 119mm EXT SANITARY ELBOW E2 40 1 5 119mm EXT SANITARY ELBOW 193746 16 bar 1 4 194594 1 8 194591 5 1 1 9 194591 1 1 10 1 1 1 2 SANITARY CLAMP 192009 3 194591 194591 6 194276 OUTLET MANIFOLD 1 194275 INLET MANIFOLD 1 194594 REMARKS 1 104168 7 192008 2 10 1 PART NUMBER DESCRIPTION QTY PARTS LIST PRV and Manifold Assembly 77 3215 R5 5 12 ...

Page 13: ...EN KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3215 R5 5 13 40 www carlisleft com ...

Page 14: ...5588 9 PARTS LIST Mechanical Assembly ITEM PART NUMBER DESCRIPTION QTY REMARKS 4 192634 2 4 177020 13 MUD GUARD WASHER STST 11 165686 4 6 165988 2 163161 4 12 M12 x 50 GRUB SCREW M10 x 30 CAP HEAD SCREW M8 x 20 CAP HEAD SCREW M16 x 30 CAP HEAD SCREW M8 x 30 GRUB SCREW 165100 10 7 165371 4 1 6 165123 6 5 165108 4 SPRING RETAINING WASHER 192400 15 2 SHAFT CLAMP ASSY 192668 22 M8 x 20 BUTTON HEAD CAP...

Page 15: ...193130 29 193696 1 28 193105 SPRING KEEP ASSEMBLY 4 193104 CARRIAGE SPRING 4 31 33 194540 SPACER 4 2 ITEM PART NUMBER DESCRIPTION QTY REMARKS 1 8 6 mm EXTENDED ELBOW Ø10 x 1 4 BSPT EXT ELBOW Ø40 SHAFT COUPLING SPACER PARTS LIST Mechanical Assembly 77 3215 R5 5 15 40 www carlisleft com ...

Page 16: ...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 3215 R5 5 16 40 www carlisleft com ...

Page 17: ...193120 Part No 6 To be tightened using tool 193119 Part No 11 To be pressed into housing using tool 193121 Part No 12 Remove inner race grease 502375 KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3215 R5 5 17 40 www carlisleft com ...

Page 18: ... M50 BEARING LOCKNUT 3 5 192617 BEARING CLAMP 1 165571 10 M6 x 20 CAP HEAD SCREW M6 x 16 CAP HEAD SCREW M6 SPRING WASHER BEARING CAP 1 6 193437 12 Ø50 x Ø110 x 44 4 SHAFT BEARING 1 BELL HOUSING MACHINING 194539 7 195636 15 194512 SHAFT ASSEMBLY 1 192639 1 1 9 1 1 192655 BOTTOM BEARING HOUSING 192600 8 192644 1 14 1 CONSTANT VELOCITY CAM 18 1 12 M10 x 70 CAP HEAD SCREW 1 17 192606 BASE SHAFT 1 4 19...

Page 19: ...EN 77 3215 R5 5 19 40 www carlisleft com ...

Page 20: ... 5 2 LINEAR BEARING SPACER 192615 10 4 192652 6 192610 CAM FOLLOWER PIN 1 4 192618 CARRIAGE ADAPTOR 1 PART NUMBER 4 8 1 11 M8 LOCKWASHER M8 x 20 CAP HEAD SCREW M8 x 25 CAP HEAD SCREW M16 NYLOC NUT 1 8 GREASE NIPPLE SLIP ON 1 8R 6mm PUSH IN ELBOW 2 FOLLOWER GUARD WASHER REMARKS 192608 LH CARRIAGE END 1 6 192607 CARRIAGE MIDDLE 1 DESCRIPTION QTY 1 FOLLOWER NUT WASHER 192612 7 77 3215 R5 5 20 40 www ...

Page 21: ...inal assembly to give correct orientation for hose connection to grease nipple Bolts remain loose tightened when mechanical assembly is complete Orientate bearing so black section along the body is aligned to the block s side KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3215 R5 5 21 40 www carlisleft com ...

Page 22: ...REW REMARKS 50 5 x 2 62 O RING 192596 192632 194237 PISTON SEAL 1 9 192551 10 192647 192648 19 18 1 41 0 x 1 78 O RING OUTLET CYLINDER PARTS LIST E2 30 Fluid Section ITEM 4 165044 8 1 BALL CHECK SPRING DESCRIPTION QTY PART NUMBER 192505 2 2 16 4 163921 164472 3 2 M8 SPRING WASHER M6 SPRING WASHER M12 SPRING WASHER M12 x 40 CAP HEAD SCREW Ø1 3 8 ST ST BALL 12 42 x 1 78 O RING 1 4 BSP HEXAGON PLUG 1...

Page 23: ...EN KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3215 R5 5 23 40 www carlisleft com ...

Page 24: ...ISTON SEAL 1 20 192790 1 BALL CHECK SPRING 3 2 E2 40 Fluid Section ITEM PART NUMBER DESCRIPTION QTY REMARKS PARTS LIST 164472 M8 x 25 CAP HEAD SCREW 5 165108 4 8 165960 6 7 165087 12 192626 OUTLET CAGE 1 19 192789 OUTLET CYLINDER 1 18 194244 PISTON ASSEMBLY 171788 INLET SPRING KEEP 192629 13 1 2 4 8 15 163921 160513 1 4 50 5 x 2 62 O RING 41 x 1 78 O RING PTFE Ø 1 3 8 ST ST BALL 12 42 x 1 78 O RIN...

Page 25: ...EN KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3215 R5 5 25 40 www carlisleft com ...

Page 26: ...2805 2 1 160513 4 162854 PARTS LIST E2 30 8 193626 FLUID PISTON 1 7 192631 3 1 1 63 17 x 2 62 O RING Use a 32mm Single Hex Socket when tightening or removing ball cage from Piston Piston Assembly PISTON INLET SEAT 5 171784 1 1 75 ST ST BALL KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3215 R5 5 26 40 www carlisleft com ...

Page 27: ...IST 82 22 x 2 62 O RING 50 52 x 1 78 O RING 1 75 ST ST BALL 160513 BALL CHECK SPRING 1 2 194112 FLUID PISTON 1 Use a 32mm Single Hex Socket when tightening or removing ball cage from Piston 5 1 INLET SPRING KEEP 192629 6 63 17 x 2 62 O RING KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3215 R5 5 27 40 www carlisleft com ...

Page 28: ...rip bellows lightly by hand and tighten the nut with a 1 A F spanner until the nut contacts the bellows shoulder Screw Item No 2 assembly spigot onto the piston shaft grease spigot with AMGD 010 Using Item No 7 push bellows over spigot until located in groove PARTS LIST Shaft Bellows Assembly ITEM PART NUMBER DESCRIPTION QTY REMARKS 192374 RETAINING NUT 1 KEY Reverse for assembly LOCTITE TORQUE MA...

Page 29: ...s in addition to the recommended spare parts kits Fluid Pressure Output Requirement Maintenance General Maintenance Before any maintenance always switch off the pump and secure against any unintentional start up NOTE The working life and thus the expected life prior to replacement of parts within a Paint Pump are greatly affected by three main factors Abrasiveness of Fluid Pumped Pump Duty Cycle 7...

Page 30: ...d Cam followers for excessive wear replace if excessive wear can be seen 3 Monthly While running apply 502375 grease to cam follower bearings 8 strokes of a standard cartridge grease gun 502373 6 Monthly Grease Main Shaft Bearing with 502375 grease Inspect Linear Bearings Rod Cam and Cam followers for excessive wear replace if excessive wear can be felt or seen Daily Check for any fluid leakage We...

Page 31: ...pplied factory fitted with oil and is a service free unit However if seals start to leak and oil level is reduced both the affected seal and oil need to be replaced as a general overhaul of the unit The unit must be removed to be drained maintained and filled with oil If changing the oil place a suitable container underneath the plug for draining Maintenance 77 3215 R5 5 31 40 www carlisleft com ...

Page 32: ...be made using spare parts supplied from the manufacturer in order to guarantee the original type of protection WARNING Wait until the unit has cooled sufficiently after stopping and isolation Electric Motors The electric connections must be correctly locked to avoid resistance increases with consequent contact overheating For the Ex motors the repairs of parts directly involved on the protection a...

Page 33: ...section Carriage does not maintain contact with cam Spring tension insufficient Gearbox Oil leaking Defective gasket on gear unit cover Check and correct the oil level from the motor flange Defective gasket Return gearbox from the gear unit flange Gear unit not ventilated Gearbox Output shaft does not rotate even though the motor is running from the gear unit cover Fault Finding Mechanics Check ve...

Page 34: ...not seating correctly Replace bellows seal check piston seal replace as necessary Main shaft bearings worn Cam follower worn Cam direction incorrect Remedy Fluid Section Pump runs but lack of pressure Worn piston seals Replace piston seals Inverter Unit or safety interlocks tripped Inspect clean and or replace balls and seats Pump will not run No power Check electrical supply Inverter Unit or safe...

Page 35: ...s between 60 to 80Hz to ensure any trapped air is correctly vented While running apply 502375 grease to cam follower bearings 8 strokes of a standard cartridge grease gun 502373 While running apply 502375 grease to main shaft bearing 40 strokes of a grease gun on a new bearing and 6 pumps on a bearing in current use Connect electric motor to a suitable electrical supply Fit the gearbox vent plug T...

Page 36: ...all the necessary components to service mark one and mark two fluid pistons 250612 Linear Guide and Rod Kit Constant Velocity Cam Please note 502672 192688 Auto Lubrication Kit Cam Follower Bearing 250611 Spare Parts List Cam Follower Bearing Kit Fluid section seal kit E2 30 250738 Fluid Section overhaul kit E2 30 250786 Fluid Section overhaul kit Check Main Parts List for details of Individual Ki...

Page 37: ... Cam Follower Collet Connector 502373 ACCESSORIES PART NUMBER DESCRIPTION REMARKS 192009 194237 502376 Grease for Linear Bearings 192720 Sensor Manifold Grease for Cam Follower Main Bearings 300mm Extension Main Bearings 502375 4 20 mA 0 25 bar Pressure Feedback 192547 194238 E2 40 Fluid Piston Seal E2 30 Fluid Piston Seal 1 5 Sanitary Clamp 1 5 Sanitary Gasket 77 3215 R5 5 37 40 www carlisleft co...

Page 38: ...t 502508 502509 502510 502511 502512 Shaft Assembly Tool 502377 Bellows Assembly Tool M8 Torx Security Screwdriver for Cover DESCRIPTION REMARKS 192450 FOC with a New Pump 502508 Top Bearing Locknut Tool 502512 502377 502382 PART NUMBER 502509 Bottom Bearing Locknut Tool 77 3215 R5 5 38 40 www carlisleft com ...

Page 39: ...EN NOTES 77 3215 R5 5 39 40 www carlisleft com ...

Page 40: ...POLICY This product is covered by Carlisle Fluid Technologies materials and workmanship limited warranty The use of any parts or accessories from a source other than Carlisle Fluid Technologies will void all warranties Failure to reasonably follow any maintenance guidance provided may invalidate any warranty For specific warranty information please contact Carlisle Fluid Technologies Carlisle Flui...

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