- Smart Pumps E2-60 - Service Manual - 77-3228 [ English ]
77-3228
E2-60
Electric Drive Pump
104085 - (EU Model)
104086 - (USA Model)
104087 - (Japan Model)
104279 - (China Model)
EN
Obey local or municipal regulations for product recycling and disposal.
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 Binks representative for additional copies of this manual.
READ ALL INSTRUCTIONS BEFORE OPERATING THIS PRODUCT
ADDITIONAL RESOURCES
For additional information or copies of your service manual, please visit us online at:
binks.com/en/library
Or use this QR code with your mobile device:
XXXXXXXX
Insert
QR
code
77-3228 R4.2 (04/2025) 2/40 www.binks.com
EN
Machinery Directive 2006/42/EC
ATEX Directive 2014/34/EU
EMC Directive 2014/30/EU
by complying with the following statutory documents and harmonised standards:
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN 12621:2006+2010 Machinery for the supply and circulation of coating materials under pressure - Safety requirements
EN ISO 80079-36:2016 Explosive Atmospheres- Part 36:Non Electrical equipment for explosive atmospheres-Basic methods
and requirements.
EN ISO 80079-37:2016 Explosive Atmospheres- Part 37: Non Electrical equipment for explosive atmospheres - protection by
methods c, b and k.
EN 1127-1:2019 Explosive atmospheres - Explosion prevention - Basic concepts
EN 60079-0:2018 Explosive atmospheres - 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 any applicable local codes of practice.
Executive President: Engineering and
Operations, Shoreview, MN, 55126. USA
10/04/25
This Declaration of Conformity / Incorporation is issued
under the sole responsibility of the manufacturer:
This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:
EU Declaration of Conformity
Signed for and on behalf of Binks
U.K. Ltd:
Document Part No.
.
Binks U.K. Limited,
Ringwood Road,
Bournemouth, BH11 9LH. UK
Representative authorised to compile the technical file President @. Binks France SAS
5 Place Pierre Semard, 94130 Nogent sur Marne , Paris, France
Product Description / Object of Declaration: Electric Pump E2-7, E2-15 XXX, E2-20, E2-30, E2-40, E2-60, EV2-
15, EV2-30, E4-60, E4-100
This Product is designed for use with: Solvent & Waterbased Materials
Suitable for use in hazardous area: Zone 1/Zone 2
Protection Level: Ex h IIB T4 Gb X (Pump)
II 2 G Exd/Exde IIB T4 IP55 (Motor) CE0722
II 2 GD ck T4 (Gearbox)
Notified body details and role: Element Materials Technology Rotterdam B.V. (2812)
F. A. Sutter
Lodging of ATEX Technical file
77-3228 R4.2 (04/2025) 3/40 www.binks.com
EN
This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:
UKCA Declaration of Conformity
Electric Pump E2-7, E2-15 XXX, E2-20, E2-30, E2-40, E2-60, EV2-
15, EV2-30, E4-60, E4-100
Suitable for use in hazardous area: Zone 1/Zone 2
Protection Level:
Signed for and on behalf of Binks
U.K. Ltd:
Document Part No.
.
Product Description / Object of Declaration:
F. A. Sutter
10/04/25
Supply of Machinery (Safety) Regulations 2008
Equipment and Protective Systems Intended for use in Potentially Explosive Atmospheres Regulations 2016
Electromagnetic Compatibility Regulations 2016
by complying with the following statutory documents and designated standards:
BS EN ISO 12100:2010 Safety of Machinery - General Principles for Design
BS EN 12621:2006+2010 Machinery for the supply and circulation of coating materials under pressure - Safety requirements
BS EN ISO 80079-36:2016 Explosive Atmospheres- Part 36:Non Electrical equipment for explosive atmospheres-Basic methods
and requirements.
BS EN ISO 80079-37:2016 Explosive Atmospheres- Part 37: Non Electrical equipment for explosive atmospheres - protection
by methods c, b and k.
BS EN 1127-1:2019 Explosive atmospheres - Explosion prevention - Basic concepts
BS EN 60079-0:2018 Explosive atmospheres - Equipment. General requirements
BS EN 60079-1:2014 Explosive atmospheres - Equipment protection by flameproof enclosures d
BS EN 60079-7:2015 Explosive atmospheres. Equipment protection by increased safety e
BS 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 any applicable local codes of practice.
Executive President: Engineering and
Operations, Shoreview, MN, 55126. USA
Element Materials Technology Warwick Ltd. UK. (0891)
This Declaration of Conformity / Incorporation is issued
under the sole responsibility of the manufacturer:
Binks U.K. Limited,
Ringwood Road,
Bournemouth, BH11 9LH. UK
This Product is designed for use with: Solvent & Waterbased Materials
Ex h IIB T4 Gb X (Pump)
II 2 G Exd/Exde IIB T4 IP55 (Motor) CE0722
II 2 GD ck T4 (Gearbox)
Approved body details and role:
Lodging of UKEX Technical file
77-3228 R4.2 (04/2025) 4/40 www.binks.com
EN
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE
OPERATOR OF 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 be
dissipated through 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 electric 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 product contains chemicals
known to the state of California to cause cancer and birth defects or
other reproductive harm.
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.
In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as
follows:
WARNING CAUTION
WARNING
Read the following warnings before using this equipment.
KNOW WHERE AND HOW TO SHUT
OFF THE EQUIPMENT IN CASE OF AN
EMERGENCY.
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.
NOTE
PINCH POINT HAZARD. Moving parts
can crush and cut. Pinch points are
any areas where ther are moving
parts.
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.
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.
77-3228 R4.2 (04/2025) 5/40 www.binks.com
EN
E2-60 Maximum fluid pressure: *
Fluid Output @ 80 HZ [40 cycles/min]
NOTE
60 l/m [16.0 US gal/m]
AC Induction Electric Motor - EU Model
1 ½'' Sanitary
SHC 630 Synthetic Oil
SPECIFICATION
1.50 l [0.40 US gal]
Nominal pump stroke: 50mm [1.97 ins]
20 bar [290psi]
400V 3PH 3.0 kW @ 50HZ
3.0 kW 4Pole 1400 RPM
3.0 kW 4Pole 1400 RPM - Japan Model Rated 20 to 80 Hz (c/w thermisters)
AC Induction Electric Motor - USA Model
Rated 20 to 80 Hz (c/w thermisters)
2 bar [29 psi]
Reduce Maximum working pressure by 2 bar [29 psi] when using in Open Loop Flow Mode
Gearbox Oil (EU Model) Synthetic 220 (typically Agip Blasia S)
1 ½'' Sanitary
Fluid inlet connection: 'A'
E2-60 Nominal flow volume / cycle:
Fluid Output @ 20 HZ [10 cycles/min]
295kg [650lbs]
* Pressure when used in 'Smart Mode' (Closed Loop Pressure Mode)
Gearbox Oil (USA Model)
Fluid outlet connection: 'B'
Class 1, Group D.
Total Weight of Pump (inc electric motor)
Max. Inlet Pressure
e.g. E2-60 Maximum Set Pressure of 18 bar to operate Pump on a 24/7 basis
Gearbox Ratio: 61:1
EEx d 11B T3
15 l/m [4.0 US gal/m]
460V 3PH 5 Hp @ 60HZ
77-3228 R4.2 (04/2025) 6/40 www.binks.com
EN
DIMENSIONS AND 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
1
3
0
4
-
1
5
3
0
77-3228 R4.2 (04/2025) 7/40 www.binks.com
EN
A Pressure 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 e.g. blocked paint filter, otherwise
Pump warranty may be invalidated. This is necessary to protect the Pump mechanics from overload. An
adapter to mount a pressure switch and pressure sensor is available, see accessories.
NOTE:
The Pump Units are designed for location in Zone 1 Hazardous areas, ATEX Category 2.
Electrical connections must be in accordance with Local Regulations for installation in Hazardous Areas.
It is recommended that a Local Control Box is positioned in close proximity to the pump, as a convenient local
Start / Stop facility and Junction box.
INSTALLATION
The Pressure Switch is classified as simple apparatus and as such should be electrically connected as part of an
intrinsically safe electrical circuit.
If the gearbox unit will be inactive for nine months or more, prepare and store gearbox in accordance with
gearbox long term storage guidance at the end of this manual, to reduce risk of internal corrosion and early
failure.
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 main Pump Control Panel must be positioned within an Electrically Safe Area.
It is recommended that the switch setting is set to 1 bar [14.5 psi] above the maximum required pressure.
The maximum pressure setting which the Pressure Switch should be set to is 21 bar [305 psi].
77-3228 R4.2 (04/2025) 8/40 www.binks.com
EN
6.7 A
Rated Motor Power Factor 0.81
Rated Motor Efficiency 80%
Rated Motor Frequency 50 Hz
Rated Motor Current
Required Inverter Settings
Once operating temperature is reached, this device quickly changes the resistance;
Electric Motor
Rated Motor Voltage 400 V
Rated Motor Speed 1440 RPM
3.0 kW
Inverter
5 Seconds
0.1 Seconds
If improperly used, badly connected, or altered no matter how minor, their reliability could be in doubt.
The motor must be wired to provide a clockwise direction of the cam.
Electric Motors for hazardous areas are specially designed to comply with official regulations concerning the risk
of explosion.
Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into
consideration.
INSTALLATION
Only trained personnel familiar with these standards should handle this type of apparatus.
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.
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
77-3228 R4.2 (04/2025) 9/40 www.binks.com
EN
• Outlet - Ø32 - 38 I.D. [20 bar working pressure]
• Ensure the gearbox is filled with oil. (The gearbox is filled with the correct amount of oil at the factory)
• Ensure adequate air space around the Pump for maintenance and electric motor cooling requirements.
• Attach suitable flexible hoses to the inlet and outlet connections.
e.g.,
• Suction - Ø38 I.D. [-1 to 10 bar working pressure]
• Check that the oil plug on top of Gearbox has been replaced with the correct venting plug. The vent plug is
supplied in a bag attached to the gearbox.
INSTALLATION
77-3228 R4.2 (04/2025) 10/40 www.binks.com
EN
SYSTEM OPERATION
Before starting:-
• 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. Oil level check is particularly important if the gearbox has been in long term storage.
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 variable
paint usage) by dynamically adjusting the paint flow rate returning to the system paint tank, thus maintaining the
set pressure.
77-3228 R4.2 (04/2025) 11/40 www.binks.com
EN
NOTE:
3
ITEM REMARKS
USA MODEL
3 194946
DESCRIPTION
1 JAPAN MODEL
193456
6 165137
M14 x 40 CAP HEAD SCREW8
4
COVER C/W CAP FIXINGS
MANIFOLD WITHOUT PRV
(Not Shown)
1 USA MODEL
M14 SPRING WASHER (ST ST)
1
EU MODEL
JAPAN MODEL
China Model
164469
M12 WASHER 4
2
M12 SPRING WASHER (ST ST)
4
8
193710 1
1
7 164469
E2-60 MECHANICAL ASSY
PART NUMBER
192819
ELECTRIC MOTOR
(Not Shown)
GEARBOX
(Not Shown)
1
2
5
GEARBOX
(Not Shown)
ATEX GEARBOX
(Not Shown)
JAPAN MODEL
194903
9
192687 13
8
11 194907
FLUID SECTION
10
1MANIFOLD & PRV ASSEMBLY
4 164470
If the gearbox unit will be inactive for nine months or more, prepare and store gearbox in accordance with
gearbox long term storage guidance at the end of this manual to reduce risk of internal corrosion and early
failure.
2 172606
3.0KW ATEX/CCC MOTOR & ATEX
GEARBOX
1 China Model
11
2
PARTS LIST - Pump Assembly
194560
165077
M12 x 40 CAP HEAD SCREW
194921 1 EU MODEL
3.0KW ATEX MOTOR & ATEX
GEARBOX
QTY
2 192685 USA MODEL
77-3228 R4.2 (04/2025) 12/40 www.binks.com
EN
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
KEY
77-3228 R4.2 (04/2025) 13/40 www.binks.com
EN
192008 1.5'' SANITARY GASKET 8
2 192009 1 & 1 1/2 SANITARY CLAMP 8
3 193746 1.5'' ELBOW 4
4 193747 INLET MANIFOLD 1
5 193748 OUTLET MANIFOLD 1
6 193748
1
3
1 104168 1
2 192008 1.5'' SANITARY GASKET
1.5'' PRESSURE RELIEF VALVE
DESCRIPTION QTY REMARKS
193747 INLET MANIFOLD
7 1
14
OUTLET MANIFOLD
1.5'' ELBOW
10
PARTS LIST - PRV and Manifold Assembly
1 & 1 1/2 SANITARY CLAMP
ITEM PART NUMBER
10192009
1.5'' ELBOW
193746
15
194591
8 194593
1
1
ITEM PART NUMBER DESCRIPTION QTY REMARKS
1.5'' ELBOW
PARTS LIST - MANIFOLD WITHOUT PRV
77-3228 R4.2 (04/2025) 14/40 www.binks.com
EN
PRV and Manifold Assembly
MANIFOLD WITHOUT PRV
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3228 R4.2 (04/2025) 15/40 www.binks.com
EN
193750 1/8 x 16mm ADAPTER 4
193796 DRIVE SHAFT COUPLING 1
39 194585 BELL HOUSING CAM ASSY 1
194541 SPACER 4
36
37
38
34 193457 SHAFT CLAMP ASSY 2
35 193698 Ø50 COUPLING SPACER 1
193449 LINEAR BEARING ROD 2
32 193454 LEAK DETECTION HOSE ASSY 1
33 193455 CARRIAGE ASSEMBLY 2
MAIN BODY MACHINING 1
193434 CARRIAGE SPRING 4
30 193442 LINEAR SPRING PIN 2
26 192870 GREASE BULKHEAD 2
193131 1/4 - 10mm PUSH IN ELBOW 2
29
27
165958 M6 x 20 SCREW (BRASS) 2
192654 14 x 9 x 50 KEY 1
192661 1/8 - 6mm PUSH IN ELBOW 2
25 192662 Ø6 GREASE HOSE 2
192400 SPRING RETAINING WASHER 4
192441 M16 EYE BOLT 2
192634 MOUNTING FRAME 2
22 192650
17
163161 M8 AEROTIGHT NUT 4
177020 M8 MUD GUARD WASHER - STST 4
DVX-364 M8 x 20 SCREW 4
177022 M10 x 40 GRUB SCREW 4
165371 M16 x 60 SCREW 6
165588 M16 x 30 SCREW 4
165671 M10 x 20 GRUB SCREW 2
165947 M10 x 35 SCREW 6
164469 M12 x 40 SCREW 4
164470 M12 WASHER 4
165097 M16 WASHER 4
165134 M8 WASHER 4
165137 M12 SPRING WASHER 4
12
DESCRIPTION QTY REMARKS
PART
NUMBER
ITEM
14
10
13
165108 M8 SPRING WASHER 4
31
28
21
165100 M16 SPRING WASHER
3
16
23
24
4
5
6
7
8
9
12
18
19
20
165959 M6 WASHER (BRASS) 2
GREASE NIPPLE 2
193430
2
11
1
15
165123 M10 SPRING WASHER 6
PARTS LIST - Mechanical Assembly
77-3228 R4.2 (04/2025) 16/40 www.binks.com
EN
** Tighten bolts holding carriage ends once pump is fully
assembled. Check carriages slide along guide rods without
binding before fitting carriage springs.
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
**
77-3228 R4.2 (04/2025) 17/40 www.binks.com
EN
1 �
9 192655 1
193431
Ø58 x Ø80 x 8 SEAL
1
6 192640
1
1
14
12
10 192656 M50 BEARING LOCKNUT 1
193440
193437
1
TOP SHAFT
163952 M6 x 20 SCREW 6
M10 x 70 SCREW 1016557117
11 BELL HOUSING MACHINING
13
BOTTOM BEARING HOUSING
CONSTANT VELOCITY CAM
BOTTOM SHAFT
1
193435
193436
1
Ø50 x Ø110 x 44.4 SHAFT BEARING
Ø45 x Ø100 x 36 SHAFT BEARING
�1926447
2
SHAFT ASSEMBLY 1
192616 BOTTOM BEARING CAP
194511
192650 GREASE NIPPLE 1
1
8
3
4 192617
ITEM PART NUMBER DESCRIPTION QTY REMARKS
1 163951 M6 x 16 SCREW 6
1 �
TOP BEARING CAP 1
5 192639
M45 BEARING LOCKNUT
15
16
PARTS LIST - Bell Housing & Shaft Assemblies
77-3228 R4.2 (04/2025) 18/40 www.binks.com
EN
Part No. 10 To be tightened using tool 502508
NOTE:
Part No. 9 To be tightened 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
Bell Housing & Shaft Assemblies
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3228 R4.2 (04/2025) 19/40 www.binks.com
EN
3 165947 M10 x 35 CAP HEAD SCREW 6
9 192661 11/8 - 6mm PUSH IN ELBOW
2
M10 x 25 CAP HEAD SCREW
M20 NYLOC NUT
M20 SPRING WASHER
M10 SPRING WASHER
6 177012 2
GREASE NIPPLE7 192649
4
193439
5
192651
DESCRIPTION
CIRCLIP
1
1
2
1
2
1
1
2
2
165123
165139
ITEM PART NUMBER
1
1
SPACER
CARRIAGE ADAPTOR
�
215
16
17
193450
193451
193600
193601
8
10
6
193448
CAM FOLLOWER PIN
PLUG - 1/8 BSP
LINEAR BEARING
1
4
�
166158
177011
�
QTY REMARKS
193103
193438
12
�
CARRIAGE END
FOLLOWER NUT WASHER
193441
CARRIAGE CENTRE
CAM FOLLOWER
PARTS LIST - Carriage Assembly
11
13
14
18
LINEAR BEARING 4
77-3228 R4.2 (04/2025) 20/40 www.binks.com
EN
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3228 R4.2 (04/2025) 21/40 www.binks.com
EN
M14 x 45 CAP HEAD SCREW
M14 x 45 CAP HEAD SCREW
Ø1 3/8'' BALL
M8 SPRING WASHER
M14 SPRING WASHER
8
9
1
16
��1
INLET SPRING KEEP
2
1
192629 ��
Ø12.42 X 1.78 O-RING
1
HEXAGON PLUG - 1/4 BSP
11
1770326
ITEM PART NUMBER DESCRIPTION QTY REMARKS
1
OUTLET CYLINDER
119417719 SHAFT/BELLOWS ASSY
18 INLET CYLINDER
165108
171788
193690 1
1
��2
4
�
4
192551
12
1
1194239
193691
4
192626
1925058
OUTLET CAGE
OUTLET CHECK
M8 x 25 SCREW
160513
15
PISTON SEAL20
��1192648
1
SEAT �
17
13
��
164472
165077
192595
1770337
5
82
3
PISTON ASSEMBLY
10
192632
193651
Ø41 X 1.78 O-RING
Ø50.5 X 2.62 O-RING
1
14 192647
PARTS LIST - Fluid Section
��
SPRING
1
8
77-3228 R4.2 (04/2025) 22/40 www.binks.com
EN
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3228 R4.2 (04/2025) 23/40 www.binks.com
EN
Ø50.52 X 1.78 O-RING
Ø107.62 X 2.62 O-RING
Ø63.17 X 2.62 O-RING
��1PISTON BALL CHECK SPRING
1
1
INLET SPRING KEEP
ITEM PART NUMBER DESCRIPTION
��
1
7
Ø128 FLUID PISTON
BALL CAGE �1
Ø1.75'' BALL
��1
193653
�
5
1926296
SEAT192631
193652
�
��
��4 162807
1605131
8
171784
1
QTY REMARKS
9
Use a 36mm Single Hex Socket
when tightening or removing ball
cage from Piston.
1
2
PARTS LIST - Piston Assembly
1628063
1162805
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3228 R4.2 (04/2025) 24/40 www.binks.com
EN
4
1 �SHAFT SEAL
193452
BELLOWS POSITIONING TOOL
193453
1
1
1
1
QTY
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. 7 (assembly
spigot) onto the piston shaft
(grease spigot with AMGD-010).
5
DESCRIPTION
KNIFED BELLOWS
REMARKS
3
2
ITEM PART NUMBER
TOOL
BELLOWS SPACER
RETAINING NUT
TOOL6 502682
�
PISTON SHAFT
Using Item No. 6, push bellows
over spigot until located in
groove.
192881
192887
193445
7
PARTS LIST - Shaft & Bellows Assembly
502681
1
BELLOWS ASSEMBLY SPIGOT
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3228 R4.2 (04/2025) 25/40 www.binks.com
EN
The two components which are more greatly affected by the above criteria than any other components in the
pump are:
it is therefore recommended that these two items are stocked as spare parts in addition to the recommended
spare parts kits.
NOTE
Before any maintenance always switch off the pump and secure against any unintentional start up.
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: -
The Main Piston Seal and the Cam Follower ;
• Fluid Pressure Output Requirement
• Pump Duty Cycle
• Abrasiveness of Fluid Pumped
Maintenance
77-3228 R4.2 (04/2025) 26/40 www.binks.com
EN
While running, apply (502375) grease to cam follower bearings, 8 strokes of a
standard ‘cartridge’ grease gun (502373).
Operation
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
3 Monthly
Maintenance schedule
Inspection
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.
Inspect Piston and Replace Piston Seals / Bellows / Springs.
Inspect Piston & Outlet Ball Checks, replace as necessary.
Inspect Linear Guide Bearing and Guide Rails for excessive wear.
Inspect Cam and Cam followers for excessive wear, replace if excessive wear can
be seen.
Replace main shaft bearings. Linear Guide Bearings, Guide Rails and Cams if
excessive wear can be seen.
Stop the pump and apply (502376) grease to linear bearings, 6 strokes of a
standard ‘cartridge’ grease gun (502514).
Check for any excessive mechanical noise
Check for excessive fluid pressure pulsation
Check oil level within gearbox
Weekly
Maintenance
Annually
77-3228 R4.2 (04/2025) 27/40 www.binks.com
EN
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 draining.
After filling with fresh oil, refit the level and/or drain plugs and clean up any oil spillage.
If changing the oil place a suitable container underneath the plug for draining.
Note:
The unit must be removed to be drained, maintained and filled with oil.
WARNING
Maintenance
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.
Maintenance - Gearbox
Wait until the unit has cooled sufficiently after stopping and isolation.
77-3228 R4.2 (04/2025) 28/40 www.binks.com
EN
The join surfaces have just to be cleaned and, in order to avoid corrosion or water entrance.
• Quality control department, for the checks and the tests, requested after repairs.
• Factory equipment with tooling and facilities, suitable to make repairs.
• Sufficient technical knowledge of these motors.
Wait until the unit has cooled sufficiently after stopping and isolation.
• 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.
Maintenance - Motor
WARNING
Electric Motors
Repair procedures of the Ex motors - 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:
Maintenance of Ex Motors - are reported by EN 60079-17 standard, in particular:-
• 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 from the manufacturer.
• The replacement of seals and of components for cable entrance would be made using spare parts, supplied
from the manufacturer, in order to guarantee the original type of protection.
• All the screws, used to assemble the parts of the motors and of the terminal box, must be completely
tightened.
• The insulation air-distance and the surface-distance between conductors, required by the standards, must be
respected.
• The electric connections must be correctly locked to avoid resistance-increases, with consequent contact
overheating.
77-3228 R4.2 (04/2025) 29/40 www.binks.com
EN
b) Fluid seal friction or piston
movement prevented
b) Check fluid section
c) Check both coupling hub locking
screws are tightened to specified
torque. Replace inner coupling
spider.
c) Loose or worn drive shaft coupling
Carriage does not maintain contact
with cam; Noisy Changeover
a) Spring tension insufficient
c) Check vent is clean/fitted and not
the transportation plug
b) Return gearbox
a) Retighten screws on gear unit
cover.
Gearbox Oil leaking from ventilator Unit overfilled with oil. Check and correct the oil level
a) Check and replace springs
Grease bearing or replace if damage
is too great
Bearing needs lubrication
Cam Followers bearing generating
heat / noise
• from the motor flange
• from the gear unit cover
RemedyPossible CauseSymptom
Fault Finding
a) Defective gasket on gear unit
cover.
• from the output oil seal
• from the gear unit flange
c) Gear unit not ventilated
b) Defective gasket.
Mechanics
Gearbox Output shaft does not
rotate, even though the motor is
running.
Drive between shafts in the gear unit
interrupted
Return the unit for repair and replace
gearbox
Gearbox Oil leaking
77-3228 R4.2 (04/2025) 30/40 www.binks.com
EN
c) Cam profile worn down
b) Main shaft bearings worn
a) Ball checks not seating correctly.
Fault Finding
a) Check o-rings and hose
connections
b) Replace piston seals.
c) Inspect, clean and/or replace balls
and seats.
a) No power
b) Inverter Unit or safety interlocks
‘tripped’
a) Check electrical supply
b) Check inverter and fault
conditions
a) Worn piston seals
b) Worn balls and / or seats
a) Replace piston seals.
b) Inspect, clean and/or replace balls
and seats.
Bellows seal failure
Replace bellows seal, check piston
seal, replace as necessary
Fluid Section
Pump will not ‘Prime’
a) Air entering the suction
hose/manifold
b) Worn piston seals
c) Ball checks not seating correctly.
a) Inspect, clean and/or replace balls
and seats.
b) Inspect, clean and/or replace
main bearings
c) Replace cam
d) Cam direction incorrect d) Remove shaft assembly and
rebuild with correct cam orientation
Excessive Pressure Pulsation
Pump will not run
Pump runs, but lack of pressure
RemedyPossible CauseSymptom
Paint leaking from inside cover
77-3228 R4.2 (04/2025) 31/40 www.binks.com
EN
1
2
3
4
5
6
7
8
9
however, some material will remain within the fluid cylinders and manifolds.
If required to finally remove any paint from the pump, place the supply hose in a compatible solvent and
run the pump until sufficiently clean.
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).
Check for any leaks and mechanical noises.
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.
Fluid Drain Down
1
Allow the pump to run for about 10 minutes 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).
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent
manufacturer.
Fit the gearbox vent plug.
Stop the pump (turn off the electric motor);
2 Disconnect the inlet & outlet hoses and position securely into a suitable container.
4
3
The pump will now have most of the paint removed;
isolate the paint supply and place a suitable container underneath the hose to prevent spillage.
Turn on paint system and set back pressure regulator to zero.
WARNING
Testing and Lubricating after major overhaul
Testing and Lubricating - Qualified personnel only
Connect pump to paint system.
Connect electric motor to a suitable electrical supply.
Start the pump and run at slow speed [20Hz] for 1 minute.
Testing and Lubricating
IMPORTANT
Never allow the pump to run with a closed (‘valved off’) inlet or outlet connection
Turn the pump on at the local isolation mounted switch.
77-3228 R4.2 (04/2025) 32/40 www.binks.com
EN
CAM FOLLOWER BEARING
LINEAR GUIDE AND ROD KIT250684
CAM FOLLOWER BEARING KIT250685
Check Main Parts List for details of Individual Kit Contents
192881
REMARKSDESCRIPTIONPART NUMBERKIT No.
Recommended Replacement Spare Parts and Kits for E2-60 Pumps
250687
MAIN BEARING OVERHAUL KIT250683
# 193448
BELLOWS (FLUID SECTION)
#
# 193451
#
LINEAR BEARING
FLUID SECTION SEAL KIT250632
FLUID SECTION OVERHAUL KIT
193440 CONSTANT VELOCITY CAM
193652 Ø128mm PISTON
Spare Parts List
#
77-3228 R4.2 (04/2025) 33/40 www.binks.com
EN
192800
192720
502375
GREASE FOR LINEAR BEARINGS502376
SENSOR MANIFOLD
192547
GREASE FOR CAM FOLLOWER (& MAIN BEARINGS)
PRESSURE FEEDBACK
HOOK CONNECTORGREASE GUN FOR LINEAR BEARINGS (300mm EXTENSION)
PART NUMBER DESCRIPTION REMARKS
SMART CARD
BPR CONTROL BOX502501
502483 ELECTRICAL PANEL FOR SINGLE PUMP OPERATION INC. SMART CARD
COLLET CONNECTORGREASE GUN FOR CAM FOLLOWER (& MAIN BEARINGS)502373
502514
1.5'' SANITARY GASKET
[4 -20 mA / 0 - 25 bar] PRESSURE SENSOR
192009
192008
1.5'' SANITARY CLAMP
ACCESSORIES
77-3228 R4.2 (04/2025) 34/40 www.binks.com
EN
502508
BELLOWS ASSEMBLY TOOL
BELLOWS ASSEMBLY SPIGOT
192450
TOP BEARING LOCKNUT TOOL
M8 TORX SECURITY SCREWDRIVER FOR COVER
PART NUMBER DESCRIPTION
TOP BEARING PRESS TOOL
502511 502512 502681 & 502682
502682
FOC with a New Pump
REMARKS
502512
502681
502510
502511 BOTTOM BEARING PRESS TOOL
SHAFT ASSEMBLY TOOL
ACCESSORIES
502508 502509
BOTTOM BEARING LOCKNUT TOOL502509
502510
77-3228 R4.2 (04/2025) 35/40 www.binks.com
EN
Storage or inactivity for over nine months
Without taking additional storage measures, internal components such as bearings and gears will start to rust
due to a lack of oil circulation and / or condensation. This will result in accelerated wear during operation.
Gearboxes stored over 9 months that have not received the following long term storage measures,
will result in the voiding of the warranty.
Necessary long term storage measures (for up to 2 years):
● Rust inhibitor is applied to exposed connecting drive shaft surfaces.
● Stored in a dry environment not exposed to direct sunlight or other ultra-violet light sources.
● A warning label must be applied to the unit to indicate the gearbox has been totally filled and must be drained
to the correct level before operation.
Storage for over two years:
● For storage up to three years: relative humidity must be reduced to less than 50% in addition to the above
requirements.
● If the unit has been stored for more than two years, and / or the unit has experienced temperature variation
exceeding those above, the lubricant must be replaced before use.
● The sealing band in the vent plug must not be removed. The unit must be sealed tight.
● After two years in storage or inactivity, the gearhead must be rotated manually to avoid failure of the oil seals.
● For complete details see the gear unit operating and assembly instructions.
Gearbox Long Term Storage
● The unit must be totally filled up for the duration of storage with a compatible polyglycol synthetic
oil - lubricant type, viscosity and quantity are indicated by details on the gearbox serial plate.
● Within a temperature range of -5°C to +40°C [23°F to 104°F]and relative humidity of less than 60%.
● Protected against damage by insects and contact with aggressive or corrosive substances or atmospheres.
● Protected from the risk of falling or being fallen on to.
● In an environment free from vibration or oscillation.
77-3228 R4.2 (04/2025) 36/40 www.binks.com
EN
NOTES
77-3228 R4.2 (04/2025) 37/40 www.binks.com
EN
NOTES
77-3228 R4.2 (04/2025) 38/40 www.binks.com
EN
Korea Tel: +82313663303
Japan Tel: +81 45 785 6421
Australia Tel: +61 (0) 2 8525 7555
WARRANTY PAGE
WARRANTY POLICY
This product is covered by Binks materials and workmanship limited warranty.
The use of any parts or accessories, from a source other than Binks, will void all
warranties. Failure to reasonably follow any maintenance guidance provided, may
invalidate any warranty.
For specific warranty information please contact Binks.
For technical assistance or to locate an authorised distributor, contact one of our
international sales and customer support locations below.
REGION BINKS CONTACT
Europe, Africa, Middle East Tel: +44 (0)1202 571 111
India marketingroa@binks.com
China Tel: +8621-3373 0108
Americas Tel: 1-888-992-4657
77-3228 R4.2 (04/2025) 39/40 www.binks.com
EN
© 2025 Binks US, LLC. All rights reserved.
Binks is a global leader in innovative finishing technologies. Binks reserves the right to modify
equipment specifications without prior notice.
Binks®, DeVilbiss®, and Ransburg® are registered trademarks of Binks US, LLC.
77-3228 R4.2 (04/2025) 40/40 www.binks.com
