Binks Maple 15/6 User manual

EN
PumpMaple 15/6
104205• Model
Service Manual
77-3244 R1.0 1/20 www.carlisleft.com

EN
Product Description / Object of Declaration: Pumps - Maple, DVP, 104009, 104010, 104010-LS,
104016, 104027, 104032, 104040, 104041, 104042,
104077, 104020, 104023, 104025, 104028, 104129,
106933, 104205,
This Product is designed for use with: Solvent and water based materials
Suitable for use in hazardous area: Zone 1
Protection Level: II 2 G X IIB T4
Notified body details and role: Element Materials Technology (0891)
Lodging of Technical file
This Declaration of conformity / incorporation
is issued under the sole responsibility of the
manufacturer:
Carlisle Fluid Technologies UK Ltd,
Ringwood Road,
Bournemouth, BH11 9LH. UK
EU Declaration of Conformity

The object of the declaration described above is in conformity with the relevant Union
harmonisation legislation:
Machinery Directive 2006/42/EC
ATEX Directive 2014/34/EU
by complying with the following statutory documents and harmonized standards:
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN 12621:+A1:2010 Machinery for the supply and circulation of coating materials under pressure - Safety
requirements
EN1127-1:2011 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"
Providing all conditions of safe use / installation stated within the product manuals have been
complied with and also installed in accordance with any applicable local codes of practice.
Si
g
ned for and on behalf of Carlisle Fluid
Technologies UK Ltd:
D Smith Director of Sales (EMEA)
13/4/17
Bournemouth,BH11 9LH,UK
77-3244 R1.0 2/20 www.carlisleft.com

EN
NEVER MODIFY THE EQUIPMENT. Do
not modify the equipment unless the
manufacturer provides written
approval.
PROP 65 WARNING. WARNING:This product contains chemicals
known to the state of California to cause cancer and birth defects or
other reproductive harm.
PINCH POINT HAZARD. Moving parts
can crush and cut. Pinch points are
any areas where ther are moving
parts.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE
OPERATOR OF THE EQUIPMENT.
NOTE
Hazards or unsafe practices which could result in
severe personal injury, death or substantial property
damage.
Hazards or unsafe practices which could result in
minor personal injury, product or property
damage
Important installation, operation or maintenance
information.
WARNING
Read the following warnings before using this equipment.
In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as
follows:
WARNING CAUTION
READ THE MANUAL. Before operating finishing equipment, read and
understand all safety, operation and maintenance information
provided in the operation manual.
AUTOMATIC EQUIPMENT. Automatic
equipment may start suddenly without
warning.
WEAR SAFETY GLASSES. Failure to wear safety glasses with side
shields could result in serious eye injury or blindness. PROJECTILE HAZARD. You may be
injured by venting liquids or gases that
are released under pressure, or flying
debris.
DE-ENERGIZE, DE-PRESSURISE, DISCONNECT AND LOCK OUT ALL
POWER SOURCES DURING MAINTENANCE. Failure to de-energize,
disconnect and lock out all power supplies before performing
equipment maintenance could cause serious injury or death. KNOW WHERE AND HOW TO SHUT
OFF THE EQUIPMENT IN CASE OF AN
EMERGENCY.
NOISE LEVELS. The A-weighted sound level of pumping and spray
equipment may exceed 85 dB(A) depending on equipment settings.
Actual noise levels are available on request. It is recommended that
ear protection is worn at all times while equipment is in use.
PRESSURE RELIEF PROCEDURE.
Always follow the pressure relief
procedure in the equipment instruction
manual.
INSPECT THE EQUIPMENT DAILY. Inspect the equipment for worn or
broken parts on a daily basis. Do not operate the equipment if you
are uncertain about its condition.
OPERATOR TRAINING. All personnel
must be trained before operating
finishing equipment.
EQUIPMENT MISUSE HAZARD. Equipment misuse 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.
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 be
dissipated through proper grounding of the equipment, objects to be
sprayed and alll other electrically conductive objects in the dispensing
area. Improper
g
roundin
g
or sparks can cause a hazardous condition
and result in fire, explosion or elecrtic shock and other serious injury.
77-3244 R1.0 3/20 www.carlisleft.com

# See Note Oil: 0.1mg/m³
Weight: 45.5 kg / 91 lbs
# Note: Class 3.4.2 Air Quality (Refrigerant dried - water +3ºC@7bar) may be used, however,
above 15 cycles/min optional heavy duty mufflers 192821 or piped exhaust system should
be used, if used continuously.
Specification
Ratio: 6:1
Maximum air inlet pressure: 7 bar [101.5 psi]
Maximum fluid pressure: 42 bar [610 psi]
Nominal flow volume / cycle: 0.375 l/m [0.10 US gal/m]
Output @ 60 cycles / min: 22.5 l/m [6 US gal/m]
Dirt: 5 microns
Water: -20°C @ 7bar [940ppm]
Maximum recommended continous cycle rate:
Cycles/min 20
Maximum recommended intermittent cycle rate:Cycles/min 40
Fluid inlet connection:
Fluid outlet connection:
Compressed Air Inlet 3/8" BSPP / NPSM
A
ir consumption @ 15 cycles/min and 6 bar [87 psi] air inlet
pressure:
Max. Pump Fluid Inlet Pressure 2 bar [30 psi]
A
ir Quality ISO 8573.1 Class 3.3.2
Air volume / cycle @ 3.1 bar/45psi:
Air volume / cycle @ 6.2 bar/90psi:
9.5 l/m [0.33 SCFM]
18.5 l/m [0.65 SCFM]
283 l/m [10 CFM]
A
ir consumption @ 30 cycles/min and 6 bar [87 psi] air inlet
pressure: 566 l/m [20CFM]
EN
Sanitary
Sanitary1"
1"
77-3244 R1.0 4/20 www.carlisleft.com

EN
Dimensions and Mounting Details
MOUNTING LOCATIONS
SECTION A-A
1" Sanitary outlet
1" Sanitary inlet
EARTHING POINT
AIR INLET
77-3244 R1.0 5/20 www.carlisleft.com

EN
This product should be flushed with a suitable compatible solvent prior to use.
Mount the pump securely and position the pump at a convenient height (below the lid height of the
paint container), to allow for maintenance, visual observation, and periodic inspection.
The wall mount bracket is included with all pumps.
The Pump Mounting bracket must be connected to a suitable earth ground to ensure that there is no
possibility of static build up.
Attach suitable flexible hoses to the inlet and outlet connections.
Connect a suitable 3/8" NB air hose and 1/2” Pressure Filter Regulator to the air motor.
(Filter rated at minimum 1000 l/min)
No additional air lubrication is required as piston ring lubricant is applied during assembly or repair.
If an air lubricator is used then this must be maintained.
Installation
77-3244 R1.0 6/20 www.carlisleft.com

EN
Installation
Set the pump speed to a slow cycle rate and prime the pump to remove any air before increasing
pressure.
Inspect for any air or fluid leaks.
Set the pump cycle rate to achieve the required paint volume and then adjust the system back
pressure regulator and pump air pressure to achieve the desired system fluid pressure.
A Back Pressure Regulator should be mounted in the paint system return line.
The return line ‘back pressure’ regulator responds to the changes in system fluid flow demand, (due to
variable paint usage) by dynamically adjusting the paint flow rate returning to the system paint tank,
thus maintaining the set pressure.
If an air blow out system is used, never exceed 2 bar [29 psi] on the inlet of the pump.
Exhaust kits are available for these pumps if the air exhaust is required to be piped away from the
pump rather than exhausting locally through the mufflers.
77-3244 R1.0 7/20 www.carlisleft.com

EN
2
M12 16
M8 8
1" 2
1/4" 4
1" 2
1
2
1
1
1
2
Ø70 2
1
2
2
2
2
3
17
18
71" 
4
4
5
68
8
16
8

10
12
8
94
11 6
ITEM QTY REMARKS
2
1
PART NO. DESCRIPTION
Parts list - Pump Assembly
25 41-4404
193775
#
21
22
23

20 4
19
13
14 
15
24
194179
194242
194845
194971
194974
194976
194979
RIVET
M12 x 50
SPRING WASHER
SPRING WASHER
SOCKET HEAD CAP SCREW
M8 x 65 SOCKET HEAD CAP SCREW
M12 X 110 SOCKET HEAD CAP SCREW
164838
165044
165108
177107
177109
177111
192206
192382
192505
192551
192712
192777
192816
192833
192835
193360
Ø2 x 4.75
SANITARY GASKET
BALL
Ø12.42 x 1.78 O-RING
HEXAGON PLUG
Ø37.82 x 1.78 O-RING
LABEL
OUTLET FITTING
PISTON ASSEMBLY
1 & 1 1/2 SANITARY CLAMP
AIR MOTOR ASSEMBLY
OUTLET CYLINDER
PISTON SEAL
INLET CYLINDER
BALL CAGE
SILENCER
LABEL
SEAT
OUTLET MANIFOLD
INLET MANIFOLD
77-3244 R1.0 8/20 www.carlisleft.com

EN
Pump Assembly
KEY
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= GREASE
(AGMD-010)
77-3244 R1.0 9/20 www.carlisleft.com

EN
2
1
2
2
M8 16
M8 16
M4 4
M4 4
2
2
1
6
2
2
2
2
1
2
1
1

BELLOWS LEAK
DETECTION HOSE
AIR MOTOR PISTON
28 194972 END PLATE MACHINING 2
PUSH IN ELBOW19281526
27 194293
CYLINDER STUD - LONG
19257917
#
21 192763 BELLOWS SPACER

22 192764 PUMP BRACKET
23 192799 VENT PLUG
18 192757
19 192761 CYLINDER STUD
24 192812 EXHAUST ADAPTER
165108
12 165963
16597013
8162704 SHAFT BEARING

16 192374
2
16597114
6161995 O-RING 2

Ø19.5 x 3
SPRING WASHER
9
4


Ø20.35 x 1.78
Ø4.47 x 1.78
10115-010037 POPPET ASSEMBLY
#
20115-010102 AIR VALVE ASSEMBLY
7162703 SHAFT SEAL
4
177038 M10 x 12 BUTTON HEAD CAP SCREW 4
161993
5161994
AIR CYLINDER
25 192814
DESCRIPTION
Ø117.5 x 2.62 O-RING
O-RING
O-RING
Parts list - Air Motor Assembly
ITEM PART NO. QTY REMARKS
RETAINING NUT
KNIFED BELLOWS
15
20
16199232

10
163920 4M6 x 30 SOCKET HEAD CAP SCREW
11 165528 M4 x 16 SOCKET HEAD CAP SCREW
192762
4
DOME NUT
PLAIN WASHER
SPRING WASHER
77-3244 R1.0 10/20 www.carlisleft.com

EN
ITEM 7 DETAIL
KEY
= LOCTITE = TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= GREASE
(AGMD-010)
77-3244 R1.0 11/20 www.carlisleft.com

EN
2
1
REMARKS
AIR MOTOR PISTON SEAL 1

1627021
GRUB SCREW 1165964 M12 x 402
Air Motor Piston Assembly
ITEM PART NO. DESCRIPTION QTY
3192759 PISTON SHAFT
4192760 PISTON
KEY
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= GREASE
(AGMD-010)
77-3244 R1.0 12/20 www.carlisleft.com

EN
1
2
2
2
2
2
2
1
1
1
3/8"
1
2
QUICK EXHAUST VALVE CAGE
19281313
90115-010097
VALVE BLOCK.
10 0115-010103
1/4 BSPT PIPE PLUG
11 0115-010107
1/8 BSPT PIPE PLUG
12 180584
UNIVERSAL FITTING
50115-010020
DIAPHRAGM 
60115-010021
Ø36 x 1.5 O-RING 
70115-010049
Ø20 x 2 O-RING 
80115-010073
M4 x 12 BUTTON HEAD CAP SCREW
8
10115-010015
SPOOL AND SLEEVE ASSEMBLY #
20115-010016
BUMPER 
30115-010017
MAGNET 
40115-010018
VALVE BLOCK END CAP
SPOOL AND SLEEVE O-RING
162789 6 Not Shown
QTY REMARKS
Air Valve Assembly
ITEM PART NO. DESCRIPTION
= MAGNET HAZARD
KEY
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= GREASE
(AGMD-010)
77-3244 R1.0 13/20 www.carlisleft.com

EN
1
1
Ø56.82 x 2.62 1
1.375 1
1
1
Ø70 1
1
7193188
INLET SPRING KEEP

8194111
FLUID PISTON
9194113
BALL CAGE
3162856

4162857

5171788
BALL

6192632
SEAT

Ø41.0 x 1.78 O-RING
O-RING
Fluid Piston Assembly
ITEM PART NO. DESCRIPTION QTY REMARKS
2162855

PISTON BALL CHECK SPRING
1605331
1

Ø52.07 x 2.62 O-RING
Use a 25mm Single Hex
Socket when tightening or
removing ball cage
from Piston.
KEY
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= GREASE
(AGMD-010)
77-3244 R1.0 14/20 www.carlisleft.com

EN
Pump will not run
No Air or Fluid supply Check air and fluid supply ball valves
and supply hoses.
Air piston seal worn. Replace piston seal.
Pilot valve assemblies inoperable.
Switch/interchange pilot valves to
isolate faulty pilot valve and
clean/replace.
Pilot valve assemblies inoperable. Check clean/replace Air valve.
QE diaphragm defective.
Check for constant exhaust air when
pump is not running. Check/replace
QE diaphragms.
Ball checks not seating correctly. Inspect, clean and/or replace balls
and seats.
Pump runs but has
excessive pulsation.
Air getting into fluid line, air supply restricted. Check seals and hose connections.
Check air supply
Obstructed fluid ball checks.
Remove, clean, and inspect seat,
ball, and ball cage. Replace if
suspect or worn.
Fault Finding
Symptom Possible Cause Remedy
Pump will not ‘Prime’
Air getting into the suction hose/manifold Check seals and hose connections.
Worn piston seal. Replace piston seals.
Ball checks not seating correctly. Inspect, clean and/or replace balls
and seats.
77-3244 R1.0 15/20 www.carlisleft.com

EN
Fault Finding
Symptom Possible Cause Remedy
Pump runs but has
excessive pulsation.
Worn air motor piston seals. Replace air motor piston seal.
Worn/failed air motor shaft seals. Disassemble pump as required to
replace air motor shaft seals.
Worn fluid piston seal. Replace fluid piston seal.
Air exhaust restricted. Check QE diaphragms and exhaust
outlets.
Paint leaking into
detection hose, Air
bleeding from vent
plug
Bellows seal failure Replace bellows seal
Air motor shaft seal leaking Check air motor shaft seal replace as
necessary
77-3244 R1.0 16/20 www.carlisleft.com

EN
1
1
1
1
1
1
1
# - Recommended spare parts for continually running pumps
Maintenance schedule
Inspection Operation
Daily Check for any general fluid or air leakage.
Weekly
Inspect Pump for Correct operation
Check for any excessive mechanical noise
Check for excessive fluid pressure pulsation
Perform a pump stall test to ensure correct operation.
If pump does not stall check fluid piston seals and ball checks, replace as required.
12 to 36 Months (Typically 10
million pump cycles
dependant on air quality and
abrasiveness of the paint
used)
Replace air piston seal,
Replace shaft seals & bearings.
Inspect and replace if required: Pilot Air Valves & Main Air Valve Parts.
Replace fluid piston seal,
Replace Balls,Seats and Bellows.
If air is escaping through exhaust check air motor piston seal and quick exhaust
diaphragm, replace as required.
6 Month Test
#0115-010037 Poppet Assembly 2 off per pump
#0115-010015 Main Spool & Sleeve Valve Assembly 11 off per pump
#194976 Piston seal 2 off per pump
#192579 Knifed Bellows 2 off per pump
Spares Kits for Maple 15/6 Pump
KIT No. PART NO. DESCRIPTION QTY REMARKS
250771 Fluid section seal kit
Check main parts list for
details of individual kit
contents
250772 Fluid overhaul kit
250618 Air Motor Seal Kit
250628 Control Valve Kit
77-3244 R1.0 17/20 www.carlisleft.com

EN
1
502382 Bellows assembly spigot
Bellows Replacement
ITEM PART NO. DESCRIPTION QTY REMARKS
2
1502769 Bellows positioning tool 1
Screw Item No. 2 (assembly spigot)
onto the piston shaft
Using Item No. 1, push bellows
over spigot until located in groove.
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.
12
77-3244 R1.0 18/20 www.carlisleft.com

EN
192803 1" Manifold Plug For piped exhaust
192821 1" BSP Heavy Duty Mufflers Recommended for high pump pressures
and cycle rates
1" Sanitary Gasket
194845 1 & 1 1/2" Heavy duty
Sanitary Clamp
194281 1" Sanitary -
1" NPT
(
f
)
Adapter
502608 For Shaft seal (7)
502769 Bellows Positioning Tool
AGMD-010 Kluber Isoflex Topas NB 52 Grease 50ml Tube
502382
Exhaust Tube Adapter (1.25” NB hose)
Bellows assembly spigot
Exhaust Tube Adapter (1” NB hose) For piped exhaust
193275 1"
3/4" NPT (f) Adapter
Sanitary -
Accessories
Seal Insertion Tool
ITEM PART NO. QTY
192206
192779
192820 For piped exhaust
77-3244 R1.0 19/20 www.carlisleft.com

EN
WARRANTY POLICY
Binks products are covered by Carlisle Fluid Technologies five year materials and workmanship
limited warranty. The use of any parts or accessories, from a source other than Carlisle Fluid
Technologies, will void all warranties. For specific warranty information please contact the
closest Carlisle Fluid Technologies location listed below.
Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice.
DeVilbiss®, Ransburg®, MS®, BGK® and Binks® are registered trademarks of Carlisle Fluid
Technologies, Inc.
© 2017 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 sales and
customer support locations below.
USA/Canada Mexico
www.carlisleft.eu
[email protected]
Tel: [phone]
Fax: [phone]
www.carlisleft.eu
[email protected]
Tel: [phone]
Fax: [phone]
China Japan Australia
www.carlisleft.com.cn
[email protected]
Tel: [phone]
Fax: [phone]
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[email protected]
Tel: [phone]
Fax: [phone]
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[email protected]
Tel: [phone]
Fax: [phone]
www.binks.com
[email protected]
Toll Free Tel: [phone]
Toll Free Fax: [phone]
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[email protected]
Tel: [phone]
Fax: [phone]
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[email protected]
Tel: [phone]
Fax: [phone]
United Kingdom France Germany
www.carlisleft.eu
[email protected]
Tel: [phone]
Fax: [phone]
Brazil
77-3244 R1.0 20/20 www.carlisleft.com