Binks E4-60 Service Manual Download

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• 107070
• 107072
• 107073

Service Manual

E4-60

Electric Drive Pump

(EU Model)

(USA Model)

(Japan Model)

77-3229 R4.1

www.carlisleft.com

Summary of Contents for E4-60

Page 1: ...EN 107070 107072 107073 Service Manual E4 60 Electric Drive Pump EU Model USA Model Japan Model 77 3229 R4 1 www carlisleft com ...

Page 2: ...ements 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 atmospheres ...

Page 3: ...ugh proper grounding of the equipment objects to be sprayed and alll other electrically conductive objects in the dispensing area Improper grounding or sparks can cause a hazardous condition and result in fire explosion or elecrtic shock and other serious injury NEVER MODIFY THE EQUIPMENT Do not modify the equipment unless the manufacturer provides written approval PROP 65 WARNING WARNING This pro...

Page 4: ...l m 16 0 US gal m 2 bar 29 psi Reduce Maximum working pressure by 2 bar 29 psi when using in Open Loop Flow Mode 460V 3PH 1 Hp 60HZ AC Induction Electric Motor USA Model SHC 630 Synthetic Oil Gearbox Oil EU Model Synthetic 220 typically Agip Blasia S Gearbox Oil USA Model Rated 20 to 80 Hz c w thermisters Max Inlet Pressure e g E4 60 Maximum Set Pressure of 18 bar to operate Pump on a 24 7 basis N...

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 3229 R4 1 5 36 www carlisleft com ...

Page 6: ...peration to minimise response time The Pressure Switch is classified as simple apparatus and as such should be electrically connected as part of an intrinsically safe electrical circuit An adapter to mount a pressure switch and pressure sensor is available see accessories It is recommended that the switch setting is set to 1 bar 14 5 psi above the maximum required pressure The maximum pressure set...

Page 7: ...sing device mounted within the control panel and wired to stop the motor if an over temperature occurs Rated Motor Voltage INSTALLATION Value Maximum Hz Output Once operating temperature is reached this device quickly changes the resistance Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into consideration Only trained personnel familiar with t...

Page 8: ... top of Gearbox has been replaced with the correct venting plug The vent plug is supplied in a bag attached to the gearbox The gearbox is filled with the correct amount of oil at the factory Ø50 I D 1 to 10 bar working pressure Attach suitable flexible hoses to the inlet and outlet connections Ensure the gearbox is filled with oil INSTALLATION 77 3229 R4 1 8 36 www carlisleft com ...

Page 9: ...oil level please note the the gearbox is supplied with life lubricant and does not need any maintenance SYSTEM OPERATION 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 fl...

Page 10: ... ST 1 193711 MECHANICAL ASSY 192686 E4 60 DESCRIPTION 165137 PARTS LIST COVER C W CAP FIXINGS 3 0KW ELECTRIC MOTOR Not Shown 2 194545 ATEX GEARBOX H083 GEARBOX H083 JAPAN MODEL 1 192819 2 H083 GEARBOX 3 0KW ELECTRIC MOTOR USA MODEL 1 192685 3 3 1 MANIFOLD PRV ASSEMBLY 194942 9 4 192918 3 HEX HEAD CAP SCREW 4 164469 4 192684 8 FLUID SECTION M12 x 40 7 2 194251 77 3229 R4 1 10 36 www carlisleft com ...

Page 11: ...EN KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3229 R4 1 11 36 www carlisleft com ...

Page 12: ...embly 5 192636 OUTLET MANIFOLD ITEM PART NUMBER 1 DESCRIPTION QTY REMARKS 7 2 FOOT MOUNTED PRV INLET MANIFOLD 12 10 SANITARY CLAMP 192544 3 STANDARD 4 1 192791 6 ELBOW 10 12 192029 SANITARY GASKET 4 1 192635 2 KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3229 R4 1 12 36 www carlisleft com ...

Page 13: ... ST 16 9 165588 CAP HEAD SCREW ST ST 4 10 165592 24 CAP HEAD SCREW ST ST SEAL 4 LINEAR BEARING ROD 192643 26 27 192644 2 Ø58 X Ø80 X 8 20 192603 2 21 192616 BEARING CAP 1 23 192634 2 EYE BOLT 18 192601 1 2 192441 17 TOP PLATE MACHINED 2 WASHER BRASS 165959 15 8 192400 16 SPRING WASHER GRUB SCREW 8 165660 11 4 164470 WASHER ST ST 4 5 165087 SPRING WASHER 12 6 165100 6 7 165137 4 12 163952 2 CAP HEA...

Page 14: ...192752 1 4 10mm ELBOW 2 4 CARRIAGE ASSEMBLY 4 192682 37 DRIVE SHAFT COUPLING 1 192721 38 33 192656 M50 BEARING LOCKNUT 1 1 8 6mm ELBOW 4 4 GREASE HOSE 192662 35 1 14 x 9 x 50 BEARING LOCKNUT M45 4 SHAFT CLAMP ASSY 192668 36 Parts list continued 28 192645 1 KEY 32 192655 1 ITEM PART NUMBER DESCRIPTION QTY REMARKS Ø100 x 2 5 192650 29 192653 30 192654 31 34 O RING 5 GREASE NIPPLE 8 DOWEL PIN 192661 ...

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 3229 R4 1 15 36 www carlisleft com ...

Page 16: ...165571 192606 192605 192600 PARTS LIST Shaft Assembly ITEM PART NUMBER DESCRIPTION QTY REMARKS 1 192604 1 MIDDLE SHAFT TOP SHAFT BASE SHAFT KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3229 R4 1 16 36 www carlisleft com ...

Page 17: ...lign the holes and screw in the M10 x 70 cap head screws using Loctite 243 and tighten to 65Nm Lift the assembly off of the assembly tool rotate assembly and place back onto tool to complete assembly Place the second CAM with TOP engraving facing up ensure the CAM is 3 holes radially out of pitch from the first CAM Fit top shaft align holes and screw M10 x 20 cap head screws in using loctite 243 a...

Page 18: ...13 165552 14 16 192649 192661 17 LINEAR BEARING FOLLOWER NUT WASHER CARRIAGE ADAPTOR RIGHT HAND CARRIAGE END CARRIAGE MIDDLE NYLOC NUT CAM FOLLOWER SPRING WASHER 2 3 4 7 8 9 12 15 192607 192609 192618 192612 192641 CAM FOLLOWER PIN 1 8 GREASE NIPPLE PARTS LIST Carriage Assembly 1 LEFT HAND CARRIAGE END 192611 192610 5 6 FOLLOWER GUARD WASHER 2 ITEM PART NUMBER DESCRIPTION QTY REMARKS 77 3229 R4 1 ...

Page 19: ...mplete Tighten on final assembly to give correct orientation for hose connection to grease nipple When fitting new bearings Ensure seals have been removed from inside of bearing to ensure a correct grease supply path via centre spacer Orientate bearing so black section along the body is aligned to the block s side 77 3229 R4 1 19 36 www carlisleft com ...

Page 20: ...FT BELLOWS ASSY 194237 194243 CAP HEAD SCREW ST ST 163921 SPRING WASHER SPRING WASHER SPRING WASHER 165957 OUTLET CAP OUTLET BLOCK 192621 192624 2 6 CAP HEAD SCREW OUTLET CYLINDER INLET CYLINDER 192647 19 192648 20 CAP HEAD SCREW 165960 7 BALL 192505 9 Ø12 42 x 1 78 O RING HEXAGON PLUG 8 192632 17 ITEM PART NUMBER DESCRIPTION QTY REMARKS 3 4 5 PARTS LIST 12 13 Piston Assembly 171788 192620 14 1650...

Page 21: ...EN KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3229 R4 1 21 36 www carlisleft com ...

Page 22: ... or removing ball cage from Piston PARTS LIST Piston Assembly 160513 PISTON BALL CHECK SPRING 1 REMARKS ITEM PART NUMBER DESCRIPTION QTY 1 8 171784 192631 193626 1 O RING O RING 1 1 192629 6 SEAT 1 1 1 INLET SPRING KEEP 193627 BALL 5 7 KEY Reverse for assembly LOCTITE TORQUE MAINTENANCE ORDER GREASE INTERNAL AGMD 010 GREASE 77 3229 R4 1 22 36 www carlisleft com ...

Page 23: ... shoulder Screw Item No 6 assembly spigot onto the piston shaft grease spigot with AMGD 010 PARTS LIST Shaft Bellows Assembly QTY REMARKS TOOL 192374 192579 192627 192628 192619 PISTON SHAFT SHAFT SEAL BELLOWS SPACER KNIFED BELLOWS RETAINING NUT PART NUMBER DESCRIPTION TOOL 6 502377 BELLOWS POSITIONING TOOL 7 502382 BELLOWS ASSEMBLY SPIGOT 1 2 ITEM KEY Reverse for assembly LOCTITE TORQUE MAINTENAN...

Page 24: ...ree main factors 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 The Main Piston Seal and the Cam Follower it is therefore recommended that these two items are stocked as spare parts in addition to the recommended spare parts kits NOTE 7...

Page 25: ...inear Guide Bearing and Guide Rails for excessive wear Inspect Cam and Cam followers for excessive wear replace if excessive wear can be seen 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 Check for any excessive mechanical noise Check for excessive fluid pressure p...

Page 26: ...ondition of oil seals and gaskets The gearbox is supplied 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 If changing the oil place a suitable container underneath the plug for draining The unit must be removed to be drained maintained and filled with oil ...

Page 27: ...s are reported by IEC 79 19 standard When it is not possible to make the repairs of Ex motors at the manufacturer s plant the outside workshops deputed to this task must be endowed by the necessary capability including Sufficient technical knowledge of these motors The Ex joint surfaces have not to be machined and it is not allowed to insert between them any kind of seals not foreseen or supplied ...

Page 28: ...ct the oil level Carriage does not maintain contact with cam Spring tension insufficient Check and replace springs Fluid seal friction or piston movement prevented Check fluid section Grease bearing or replace if damage is too great Bearing needs lubrication Cam Followers bearing generating heat noise Gearbox Oil leaking from the gear unit cover from the motor flange Defective gasket Return gearbo...

Page 29: ...essure Pulsation No power Check electrical supply Inverter Unit or safety interlocks tripped Check inverter and fault conditions Pump runs but lack of pressure Worn piston seals Inspect clean replace balls seats Pump will not run Main shaft bearings worn Cam follower worn Bellows seal failure Ball checks not seating correctly Cam direction incorrect Inverter Unit or safety interlocks tripped Inspe...

Page 30: ...mp turn off the electric motor isolate the paint supply and place a suitable container underneath the hose to prevent spillage Connect pump to paint system Connect electric motor to a suitable electrical supply 8 9 Fluid Drain Down 3 4 While running apply 502375 grease to cam follower bearings 8 strokes of a standard cartridge grease gun 502373 Allow the pump to run for about 10 minutes between 60...

Page 31: ...PGRADE KIT 192600 CONSTANT VELOCITY CAM Check Main Parts List for details of Individual Kit Contents AUTO LUBRICATION KIT BELLOWS REPLACEMENT KIT 250595 Pumps before serial number 14769 will have a Mark 1 constant velocity cam fitted If new cams are required cam upgrade kit must be ordered as old cam shape is no longer available As the Cam is now unidirectional the direction must be checked to ens...

Page 32: ...OR CAM FOLLOWER MAIN BEARINGS 502373 SENSOR MANIFOLD 192569 PRESSURE SWITCH 502144 GREASE FOR CAM FOLLOWER MAIN BEARINGS 502375 502376 HOOK CONNECTOR REMARKS SMART CARD 192547 4 20 mA 0 25 bar 502514 GREASE GUN FOR LINEAR BEARINGS 300mm EXTENSION COLLET CONNECTOR ACCESSORIES PART NUMBER DESCRIPTION 77 3229 R4 1 32 36 www carlisleft com ...

Page 33: ...RIVER FOR COVER FOC with a New Pump TOP BEARING LOCKNUT TOOL 502508 TOP BEARING PRESS TOOL 502510 M8 502511 BOTTOM BEARING PRESS TOOL SHAFT ASSEMBLY TOOL BELLOWS ASSEMBLY TOOL 502511 502512 502377 502382 502508 502509 BOTTOM BEARING LOCKNUT TOOL 502509 502510 ACCESSORIES 77 3229 R4 1 33 36 www carlisleft com ...

Page 34: ...EN NOTES 77 3229 R4 1 34 36 www carlisleft com ...

Page 35: ...EN NOTES 77 3229 R4 1 35 36 www carlisleft com ...

Page 36: ... Mexico Brazil www binks com info carlisleft com Toll Free Tel 1 888 992 4657 Toll Free Fax 1 888 246 5732 www carlisleft com mx ventas carlisleft com mx Tel 011 52 55 5321 2300 Fax 011 52 55 5310 4790 www devilbiss com br vendas carlisleft com br Tel 55 11 5641 2776 Fax 55 11 5641 1256 United Kingdom France Germany www carlisleft eu info carlisleft eu Tel 44 0 1202 571 111 Fax 44 0 1202 573 488 w...

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Binks E4-60, Service Manual

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