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Smart Pumps EV2-30 Manual 77-3319 EN
- Smart Pumps EV2-30 Manual 77-3319 EN [ English ]
77-3319
EV2-30
Smart Pump
104222 - Japan Model
104283 - China Model
104225 - USA Model
104226 - EU Model
INSTALLATION MANUAL
EN
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
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code
Obey local or municipal regulations for product recycling and disposal.
77-3319 R1.7 (04/2025) 2 www.binks.com
EN
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: Ex h IIB T4 Gb X (Pump)
II 2 G Exd/Exde IIB T4 IP55 (Motor) CE0722
II 2 GD ck T4 (Gearbox)
Element Materials Technology Rotterdam B.V. (2812)
Lodging of ATEX Technical file
This Declaration of Conformity / Incorporation is issued
under the sole responsibility of the manufacturer:
Binks U.K. Limited,
Ringwood Road,
Bournemouth, BH11 9LH. UK
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.
Signed for and on behalf of Binks
U.K. Ltd:
Document Part No.
.
This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:
Product Description / Object of Declaration:
This Product is designed for use with: Solvent & Waterbased Materials
Notified body details and role:
EU Declaration of Conformity
10/04/25
Executive President: Engineering and
Operations, Shoreview, MN, 55126. USA
Representative authorised to compile the technical file President @. Binks France SAS
5 Place Pierre Semard, 94130 Nogent sur Marne , Paris, France
F. A. Sutter
77-3319 R1.7 (04/2025) 3 www.binks.com
EN
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)
Approved body details and role:
Lodging of UKEX Technical file
This Declaration of Conformity / Incorporation is issued
under the sole responsibility of the manufacturer:
Binks U.K. Limited,
Ringwood Road,
Bournemouth, BH11 9LH. UK
Signed for and on behalf of Binks
U.K. Ltd:
Document Part No.
.
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
UKCA Declaration of Conformity
Element Materials Technology Warwick Ltd. UK. (0891)
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.
Product Description / Object of Declaration:
This Product is designed for use with: Solvent & Waterbased Materials
This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:
Executive President: Engineering and
Operations, Shoreview, MN, 55126. USA
F. A. Sutter
10/04/25
77-3319 R1.7 (04/2025) 4 www.binks.com
EN
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE
OPERATOR OF THE EQUIPMENT.
WARNING CAUTION NOTE
Hazards or unsafe practices which could result in
severe personal injury, death or substantial property
damage.
READ THE MANUAL. Before operating finishing equipment, read and
understand all safety, operation and maintenance information
provided in the operation manual.
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.
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.
In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as
follows:
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.
Read the following warnings before using this equipment.
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.
KNOW WHERE AND HOW TO SHUT
OFF THE EQUIPMENT IN CASE OF AN
EMERGENCY.
PACEMAKER WARNING. You are in the
presence of magnetic fields which may
interfere with the operation of certain
pacemakers.
Hazards or unsafe practices which could result in
minor personal injury, product or property
damage
Important installation, operation or maintenance
information.
WARNING
PINCH POINT HAZARD. Moving parts
can crush and cut. Pinch points are
any areas where ther are moving parts.
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.
NEVER MODIFY THE EQUIPMENT. Do
not modify the equipment unless the
manufacturer provides written
approval.
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.
PROP 65 WARNING. WARNING: This product contains chemicals
known to the state of California to cause cancer and birth defects or
other reproductive harm.
77-3319 R1.7 (04/2025) 5 www.binks.com
EN
SPECIFICATION
EV2-30 Maximum fluid pressure:
EV2-30 Nominal flow volume / cycle:
AC Induction Electric Motor- EU Model
Total Weight of Pump (inc electric motor)
1½'' Sanitary
Fluid Output @ 20 HZ [10 cycles/min] 7.5 l/m [2.0 US gal/m]
4Pole 1390 RPM @50Hz
Gearbox Oil (EU Model)
30 l/m [8.0 US gal/m]
20bar [290psi]
e.g. EV2-30 Maximum Set Pressure of 18 bar to operate Pump on a 24/7 basis
Fluid Output @ 80 HZ [40 cycles/min]
NOTE
Gearbox Ratio: 58.25:1
0.75 l [0.20 US gal]
Nominal pump stroke:
256 kg [564 lbs]
Pressure when used in 'Smart Mode' (Closed Loop Pressure Mode)
50mm [1.97 ins]
400V 3PH 1.5 Kw @ 50HZ
2 bar [29 psi]Max. Inlet Pressure
Rated 20 to 80 Hz (c/w thermisters)
Synthetic 220 (typically Agip Blasia S)
Fluid inlet connection:
Fluid outlet connection:
'A'
'B'
Reduce Maximum working pressure by 2 bar [29 psi] when using in Open Loop Flow Mode
77-3319 R1.7 (04/2025) 6 www.binks.com
EN
DIMENSIONS AND MOUNTING DETAILS
the Pump Frame must be wired to a suitable earth
ground to ensure that there is no possibility of static
build up.
Head screw for pump earth grounding;
M6 HEX.
SECTION A-A
1
3
1
8
-
1
4
2
0
A
B
77-3319 R1.7 (04/2025) 7 www.binks.com
EN
INSTALLATION
•
-
•
Attach suitable flexible hoses to the inlet and outlet connections. e.g.,
Suction - Ø38 - Ø50 I.D. [-1 to 10 bar working pressure]
It is recommended that the switch setting is set to 1 bar [14.5 psi] above the maximum required
pressure. The maximum pressure setting the Pressure Switch should be set to is 20 bar [305 psi].
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.
•
The main Pump Control Panel must be positioned within an Electrically Safe Area.
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.
•
•
Check that the rubber pin in the vent plug on top of Gearbox has been removed to allow venting. For
locations of vent, oil fill and oil drain please see gearbox operation and assembly instructions.
• Fit over temperature warning sticker delivered loose with gearbox in location specified in gearbox
operating and assembly instructions.
•
•
•
•
•
•
Outlet - Ø32 - Ø38 I.D. [20 bar working pressure]-
Ensure adequate air space around the Pump for maintenance and electric motor cooling requirements.
Ensure the gearbox is filled with oil. (The gearbox is filled with the correct amount of oil at the factory)
If the gearbox has been in long term storage, it is particularly important to check it is filled with the
correct oil to the correct level. Depending on length of storage, it may be necessary to change the oil
before use. Some gearbox variants use a special oil dip-stick delivered loose with the gearbox for
checking oil level.
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.
If the unit is inactive for over nine months, the gearbox must be prepared to avoid internal corrosion and
early failure - see page Gearbox Long Term Storage towards the end of this manual.
77-3319 R1.7 (04/2025) 8 www.binks.com
EN
INSTALLATION
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.
20 Hz
5 Seconds
0.1 Seconds
Inverter
Required Inverter Settings
Maximum Hz Output
1390 RPM
The motor is fitted with PTC temperature sensors (Thermistors).
0.73
79.3%
1.5 kW
400 V
Rated Motor Current
Only trained personnel familiar with these standards should handle this type of apparatus.
Electric Motors for hazardous areas are specially designed to comply with official regulations concerning the risk
of explosion.
If improperly used, badly connected, or altered no matter how minor, their reliability could be in doubt.
Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into
consideration.
Rated Motor Power Factor
Rated Motor Efficiency
Rated Motor Frequency
3.73A
Rated Motor Speed
Value
80 Hz
Deceleration Ramp
Rated Motor Power
50 Hz
Rated Motor Voltage
Mininmum Hz Output
Acceleration Ramp
Once operating temperature is reached, this device quickly changes the resistance;
Electric Motor
The motor must be wired to provide a clockwise direction of the cam, looking from the direction of the gearbox.
77-3319 R1.7 (04/2025) 9 www.binks.com
EN
SYSTEM OPERATION
�
�
�
�
�
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.
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.
Before starting:-
Set the pump speed to the minimum frequency 20 Hz and start the pump to remove any air from the circuit.
Confirm gearbox oil level is correct within an oil temperature range of +20°C to +40°C. For oil level
limits and location of level plug see gearbox operating and assembly instructions.
77-3319 R1.7 (04/2025) 10 www.binks.com
EN
NOTES
77-3319 R1.7 (04/2025) 11 www.binks.com
EN
9 172610 ATEX/CCC GEARBOX & MOTOR 1 China Model
PARTS LIST - Pump Assembly
1195500
EV2-30 MECHANICAL ASSY
M20 WASHER
M8 x 25 HEX HEAD CAP SCREW
M20 x 45 HEX HEAD CAP SCREW
Japan Model1
1
8
WASHER
TORQUE ARM
2
5
6
7
3
1
1
7
SPACER
177049
195488
EU Model ATEX GEARBOX & MOTOR
ATEX GEARBOX
9
195542
177125
1195514
195492
177126
1
9
9
1
PART NUMBERITEM
PRV & EV2-30 MANIFOLD KIT
195946 GEARBOX & MOTOR 1 USA Model
DESCRIPTION
1042181
4 1
195490
QTY REMARKS
77-3319 R1.7 (04/2025) 12 www.binks.com
EN
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3319 R1.7 (04/2025) 13 www.binks.com
EN
PARTS LIST - Mechanical Assembly
Ø32.92 x 3.53 O-RING
FLUID SECTION 1
2
COVER C/W CAP FIXINGS
DESCRIPTION QTY REMARKS
3
195512 2
PART NUMBER
5
1DRIVE UNIT
1954894 1
ITEM
1
1627263
104217
TORQUE ARM PIN
104216
77-3319 R1.7 (04/2025) 14 www.binks.com
EN
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3319 R1.7 (04/2025) 15 www.binks.com
EN
PARTS LIST - Drive Unit
1644714
M8 SPRING WASHER (ST ST)
M8 x 20 CAP HEAD SCREW
M16 x 50 CAP HEAD SCREW
M8 MUD GUARD WASHER
165663
8
165077 4
M16 EYE BOLT
Ø50 x Ø110 x 44.4 BALL BEARING
121639523
M5 x 12 SOCKET HEAD CAP SCREW
S.S.
M8 LOCKNUT ST ST
M6 x 20 CAP HEAD SCREW (ST ST)
M10 x 20 CAP HEAD SCREW
M14 SPRING WASHER
M6 SPRING WASHER (ST ST)1650876
REMARKS
20 192617
1
Ø45 x Ø110 x 36 ROLLER BEARING
M8 x 16 GRUB SCREW
1
11
12
(STAINLESS STEEL)8DVX-36416
8192400 SPRING RETAINING WASHER
13 165978
119264022
1
8
M8 x 30 GRUBSCREW - STST
M8 x 20 CAP HEAD SCREW (ST ST)
17
4
10
BEARING CLAMP
M10 SPRING WASHER (ST ST)
8
17700614
M16 SPRING WASHER (ST ST)
81651088
9
24165592
7
12
10114-0141791
5
1631612
1
18 192441
4
165552
17702015
BEARING CAP
(CARBON STEEL)16
8165660
M14 x 40 CAP HEAD SCREW (ST ST)
165100
DESCRIPTIONITEM
119263921
19 192616
PART NUMBER QTY
4
77-3319 R1.7 (04/2025) 16 www.binks.com
EN
PARTS LIST - Drive Unit
24
192668 2
28
3
44
19549643
Ø58 x Ø80 x 8 SEAL
SPACER
1CAM SHAFT ASSY
40
192662
195503
1
4
35 193104 8
37
8
GREASE NIPPLE192650
1
ITEM PART NUMBER DESCRIPTION QTY REMARKS
23 LINEAR BEARING ROD 4
219275233
1/8'' PLUG
Ø12 x 30 DOWEL PIN
26
Ø100 x Ø2.5 O-RING
41
1RIGHT HAND LEG
193102
2
Ø6 GREASE HOSE
30
4
192643
194540
31
8
CLAMP ASSY
1/8'' / 6mm PUSH IN ELBOW
8SPRING KEEP ASSEMBLY19310536
192644
119265529
192653
195491
DRIVE PLATE - MACHINED19550146
BASE PLATE
45 BRACE
#
19264525
1
1
1/4 / 10mm ELBOW
LEAK DETECTION HOSE
38
LEFT HAND LEG
GREASE NIPPLE
1
19548639
27 192651 2
47
M45 BEARING LOCKNUT
195499
192661
2
KEY
CARRIAGE SPRING ROD
42 195494 1
2
CARRIAGE SPRING
34
195497
1
32
195493 1
TOP PLATE
194820
77-3319 R1.7 (04/2025) 17 www.binks.com
EN
PARTS LIST - Drive Unit
48 195507 SIDE PLATE MACHINED 1
M6 x 20 SET SCREW (BRASS)51 165958 2
ITEM PART NUMBER DESCRIPTION QTY REMARKS
4
2
49
50 M6 WASHER (BRASS)
195511
165959
CARRIAGE ASSEMBLY
77-3319 R1.7 (04/2025) 18 www.binks.com
EN
Tighten bolts holding carriage ends once pump is fully assembled.
Ensure linear rods have been fully tightened and secured first!
Tighten on final assembly to give correct orientation for hose
connection to grease nipple.
*
*
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3319 R1.7 (04/2025) 19 www.binks.com
EN
PARTS LIST - Carriage Assembly
192610
CARRIAGE ADAPTOR
Ø47 x 1.75 INTERNAL CIRCLIP
CAM FOLLOWER PIN
QTY REMARKS
2
1
2
1
1
ITEM PART NUMBER DESCRIPTION
1
6
M16 NYLOC NUT (PLATED)
M8 SPRING WASHER (ST ST)
M8 x 20 SOCKET HEAD CAP SCREW
7
13
1631521
2
6
165552
192618
5
1
192608
LINEAR BEARING
6
1LH CARRIAGE END
1651082
LINEAR BEARING SPACER
14 192642
Ø72 x Ø30 x 29 CAM FOLLOWER
1/8'' GREASE NIPPLE - SLIP ON
9
8
192615
10
RH CARRIAGE END
FOLLOWER GUARD WASHER
FOLLOWER NUT WASHER
192609
4
16
15
4
11
192652
192649
192641
165553 M8 x 25 SOCKET HEAD CAP SCREW
12
4
2
1
192612
192611
192607
3
MIDDLE CARRIAGE MACHINED
1
77-3319 R1.7 (04/2025) 20 www.binks.com
EN
When fitting new bearings: Ensure seals have been
removed from inside of bearing to ensure a correct
grease supply path via centre spacer.
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
77-3319 R1.7 (04/2025) 21 www.binks.com
EN
PARTS LIST - Shaft Assembly
M10 x 70 CAP HEAD SCREW
(PLATED)
#2
4 192606 BASE SHAFT 1
PART NUMBER
CONSTANT VELOCITY CAM
5 195487 DRIVE SHAFT
1
DESCRIPTION
1926002
QTYITEM
3 MIDDLE SHAFT192604
REMARKS
1
1655711 20
Position first cam 180 degrees out
of phase with second cam.
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3319 R1.7 (04/2025) 22 www.binks.com
EN
1 2 3
1
2
3
PROCEDURE - Shaft Assembly
Place the base shaft on top of the CAM, align 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 CAM onto middle shaft (with 'TOP' engraving facing down towards the assembly tool).
Place the second CAM (with 'TOP' engraving facing up), ensure the CAM is 5 holes radially out of pitch
from the first CAM. (180 degrees offset), add drive shaft on top then align the holes and screw in the
M10 x 70 long cap head screws using Loctite 243 and tighten to 65Nm.
Assembly Tool
502512
Shaft Assembly
195486
Hold assembly tool (502512) in a vice (flats provided) and install middle shaft.
77-3319 R1.7 (04/2025) 23 www.binks.com
EN
PARTS LIST - Fluid Section
3
M6 x 25 CAP HEAD SCREW (ST ST)
M8 x 90 CAP HEAD SCREW (ST ST)
1651085
195502
19255110
9
20 194237
2
ITEM
1/4'' BSP HEXAGON PLUG (ST ST)
Ø50.5 x 2.62 O-RING
QTY
4
2
16
M12 SPRING WASHER (ST ST)
M6 SPRING WASHER (ST ST)
M8 SPRING WASHER (ST ST)
INLET CYLINDER 1
2
OUTLET CAGE
11 192620
165957
192624 OUTLET BLOCK
8
7
8
165044
163921
Ø41.0 x 1.78 O-RING
Ø100 PISTON ASSEMBLY
M12 x 40 CAP HEAD SCREW (ST ST)
Ø1 3/8'' ST ST BALL
Ø12.42 x 1.78 O-RING192505
192626 2
1
13 192625 OUTLET CAP
16
4
DESCRIPTION
BALL CHECK SPRING1605391
22
165087
8
REMARKS
165960
SEAT
8
171788 2
PART NUMBER
12
4
2
14
2
419264717
2OUTLET SPRING KEEP19263015
1
2
2
PISTON SEAL
192679
195845
192632
6
21
OUTLET CYLINDER
18 192648
8
16
19 SHAFT/BELLOWS ASSY
2
77-3319 R1.7 (04/2025) 24 www.binks.com
EN
Section through outlet block showing
location of items.
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3319 R1.7 (04/2025) 25 www.binks.com
EN
PARTS LIST - Piston Assembly
1 160539 BALL CHECK SPRING
6 192629 INLET SPRING KEEP 1
1
PART NUMBER DESCRIPTION QTY REMARKS
8
Ø50.52 x 1.78 O-RING
Ø82.22 x 2.62 O-RING
192631 1
193626
7
#
Ø63.17 x 2.62 O-RING
1
162854
171784
BALL CAGE1958449
Ø100 FLUID PISTON
PISTON INLET SEAT
5
4
162807
1
1
1
11628052
3
ITEM
Ø1.75 ST ST BALL 1
Use a 32mm Single Hex
Socket when tightening or
removing ball cage
from Piston.
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
77-3319 R1.7 (04/2025) 26 www.binks.com
EN
PARTS LIST - Shaft & Bellows Assembly
BELLOWS ASSEMBLY SPIGOT502382
PISTON SHAFT 1
7
TOOL
5
RETAINING NUT
Screw Item No. 7 (assembly
spigot) onto the piston shaft
(grease spigot with AMGD-
010).
Using Item No. 6, 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.
192628
1
TOOL1
1BELLOWS POSITIONING TOOL5023776
1
QTY REMARKS
192374
1
ITEM PART NUMBER DESCRIPTION
3 192627 BELLOWS SPACER
SHAFT SEAL
192619
4 1
KNIFED BELLOWS
1
2 192579
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
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*
PARTS LIST - PRV and Manifold Assembly
1.5'' SMART PUMP PRV
7
2
192544
192029
1.5'' SANITARY GASKET - PTFE
1.5'' SANITARY CLAMP
5
See separate Pressure Relief Valve service manual for further details.
193746
195513
3
PART NUMBER DESCRIPTION
2'' SANITARY CLAMP
2'' SANITARY GASKET - PTFE
11
192008
2
4
3
8
*
REMARKSQTY
104168
1
2
6
6
6
2
192009
194103
SIDE OUTLET BEND
ITEM
1.5'' SANITARY ELBOW
2'' - 1.5'' SANITARY PIPE REDUCER
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KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
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MAINTENANCE
�
�
�
The fluid section Piston Seals and the Cam Follower Bearings;
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: -
Before any maintenance always switch off the pump and secure against any unintentional start up.
Fluid Pressure Output Requirement
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.
Pump Duty Cycle
General Maintenance
Abrasiveness of Fluid Pumped
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MAINTENANCE
Weekly
Grease slave (top) carriages with 502375 grease.
Check gearbox temperature, (Has max temperature warning sticker changed
colour?)
3 Monthly
Grease Main Shaft Bearing with 502375 grease.
Inspect Piston & Outlet Ball Checks, replace as necessary.
6 Monthly
Check for excessive fluid pressure pulsation
Daily Check for any fluid leakage
Inspect Piston and Replace Piston Seals / Bellows / Springs.
(are shaft seals leaking?)
Inspect Linear Bearings, Rod, Cam and Cam followers for excessive wear, replace
if excessive wear can be felt or seen.
While running, apply (502375) grease to cam follower bearings, 8 strokes of a
standard ‘cartridge’ grease gun (502373).
Check condition of gearbox,
Inspect Cam and Cam followers for excessive wear, replace if excessive wear can
be seen.
Inspect Linear Guide Bearing and Guide Rails for excessive wear.
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 oil level within gearbox
Check for any excessive mechanical noise
Annually
Maintenance schedule
Inspection Operation
Note: Please also refer to gearbox operating and assembly instructions supplied with gearbox for specific
maintenance schedule requirements.
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MAINTENANCE - Gearbox
Wait until the unit has cooled sufficiently after stopping and isolation.
Every 2000 hours verify the good condition of oil seals and gaskets
Maintenance
WARNING
Gearbox
Please refer to gearbox operating and assembly instructions supplied with gearbox for specific maintenance
schedule requirements.
Unless totally filled for long term storage, the gearbox is supplied factory fitted with the correct volume of oil.
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. 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.
For locations of vent, oil fill and oil drain please see gearbox operation and assembly instructions.
Note:
General overhauls must only be done by authorised ATEX certified service personnel or companies.
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•
•
•
•
•
•
•
•
•
•
MAINTENANCE - Motor
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:
Repair procedures of the Ex motors - are reported by IEC 79-19 standard.
WARNING
The join surfaces have just to be cleaned and, in order to avoid corrosion or water entrance.
The electric connections must be correctly locked to avoid resistance-increases, with consequent contact
overheating.
Maintenance of Ex Motors - are reported by EN 60079-17 standard, in particular:-
Sufficient technical knowledge of these motors.
Electric Motors
Factory equipment with tooling and facilities, suitable to make repairs.
Quality control department, for the checks and the tests, requested after repairs.
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.
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.
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 insulation air-distance and the surface-distance between conductors, required by the standards, must
be respected.
All the screws, used to assemble the parts of the motors and of the terminal box, must be completely
tightened.
Wait until the unit has cooled sufficiently after stopping and isolation.
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FAULT FINDING
b) Check and replace piston seals,
check piston surface coating for
damage, check outlet cylinder bores
are not filled with settled out
residue.
a) Check and replace springs
a) Spring tension insufficient
Remedy
Gearbox Output shaft does not
rotate, even though the motor is
running.
Drive between shafts in the gear unit
interrupted
a) Spring tension insufficient
b) Fluid seal friction or piston
movement prevented
Mechanics
a) Check and replace springs
Symptom Possible Cause
Check and correct the oil level
Cam Followers bearing generating
heat / noise
Bearing needs lubrication
Grease bearing or replace if damage
is too great
c) Gear unit not ventilated c) Check vent is clean/fitted and not
the transportation plug
b) Return gearbox
a) Retighten screws on gear unit
cover.
b) Check fluid section
Noisy Changeover
b) Defective gasket.
a) Defective gasket on gear unit
cover.
Gearbox Oil leaking from ventilator
Gearbox Oil leaking
• from the output oil seal
• from the gear unit flange
• from the motor flange
• from the gear unit cover
Unit overfilled with oil.
Return the unit for repair and
replace gearbox
Carriage does not maintain contact
with cam
b) Fluid seal friction or piston
movement prevented
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FAULT FINDING
a) No power
b) Main shaft bearings worn
* See separate PRV service manual for details
Possible Cause
b) Inspect, clean and/or replace
main bearings
c) Check PRV seating faces for
damage.*
c) Damaged PRV seat
Pump will not ‘Prime’
Paint leaking from inside cover
Excessive Pressure Pulsation
Bellows seal failure
Remedy
Pump runs, but lack of pressure
b) Check inverter and fault
conditions
a) Check electrical supply
b) Inverter Unit or safety interlocks
‘tripped’
Replace bellows seal, check piston
seal, replace as necessary
b) Inspect, clean and/or replace balls
and seats.
a) Replace piston seals.
d) Remove shaft assembly and
rebuild following procedure on page
19
c) Replace cam
b) Worn piston seals
b) Inverter Unit or safety interlocks
‘tripped’
Pump will not run
a) Inspect, clean and/or replace balls
and seats.
d) Cam direction incorrect
a) Air entering the suction
hose/manifold
Symptom
c) Inspect, clean and/or replace balls
and seats.
Fluid Section
a) Worn piston seals
b) Replace piston seals.
a) Check o-rings and hose
connections
c) Ball checks not seating correctly.
c) Cam follower worn
a) Ball checks not seating correctly.
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EN
TESTING AND LUBRICATION
1
2
3
4
5
6
7
8
9
3
Remove paint from the system if needed to lower system pressure.
While running, apply (502375) grease to cam follower bearings, 8 strokes of a standard ‘cartridge’ grease
gun (502373).
1
Turn on paint system and set back pressure regulator to zero.
Testing and Lubricating after major overhaul
Testing and Lubricating - Qualified personnel only
Run the pump at 20 cycles/min [50 HZ] and increase the back pressure to 10 bar and run for 1 hour.
Connect electric motor to a suitable electrical supply.
Stop the pump (turn off the electric motor);
Allow the pump to run for about 10 minutes between 60 to 80Hz to ensure any trapped air is correctly
vented.
Check for any leaks and mechanical noises.
Turn the pump on at the local isolation mounted switch.
IMPORTANT
Never allow the pump to run with a closed (‘valved off’) inlet or outlet connection
Connect pump to paint system.
Fluid Drain Down
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.
isolate the paint supply and place a suitable container underneath the hose to prevent spillage.
Start the pump and run at slow speed [20Hz] for 1 minute.
The pump will now have most of the paint removed;
WARNING
Fit the gearbox vent plug, or remove rubber bung.
4
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent
manufacturer.
Disconnect the inlet & outlet hoses and position securely into a suitable container.2
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SPARE PARTS LIST
Fluid Section Overhaul Kit
192688 Auto Lubrication Kit
250597
193626
Main Bearing Overhaul Kit
Linear Guide and Rod Kit250598
250599
Replaces grease nipples
feeding lower carriages. Kit
contains two auto-greasing
units.
Recommended Replacement Spare Parts and Kits for EV2-30 Pumps
KIT No. PART No. DESCRIPTION REMARKS
Fluid Section Seal Kit250806
Constant Velocity Cam
#
Cam Follower Bearing Kit
# 192600
Ø100 Piston
Check Main Parts List for details of Individual Kit Contents
#
250807
250609 Bellows Replacement Kit
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ACCESSORIES
502376 Grease for Linear Bearings
502144 Pressure Switch
192720 Sensor Manifold
PART No. DESCRIPTION
502375
502514
192800
Grease for Cam Follower (& Main Bearings)
Grease Gun For Linear Bearings (300mm Extension)
REMARKS
Hook Connector
Collet ConnectorGrease Gun for Cam Follower (& Main Bearings)
Smart Card
192547 Pressure Feedback
192009 1.5'' Sanitary Gasket
1.5'' Sanitary Gasket
Pressure Sensor [4-20 mA / 0-25 bar]
192008
502373
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ACCESSORIES
502510 Drive Plate Bearing Press Tool
502511 Side Plate Bearing Press Tool
502512 CV Cam & Shaft Assembly Tool
Pin C spanner 502813
502886 Ø100 Piston Assembly Jig (for new piston)
502886
DESCRIPTION REMARKS
502511502510
502512
502813 16mm Shaft Tool For flats on piston shaft
502377
502377 502382
192450
502382
Bellows Assembly Tool
Bellows Assembly Spigot
PART No.
502509 Side Plate Bearing Locknut Tool
FOC with a New PumpT40 Torx Security Screwdriver for Cover192450
502509
- 95mm - 100mm Pin C spanner
Holds middle shaft when
tightening bearing locknut
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Gearbox Long Term Storage
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.
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.
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.
The sealing band in the vent plug must not be removed. The unit must be sealed tight.
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.
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.
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.
Storage or inactivity for over nine months
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NOTES
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NOTES
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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
Americas Tel: 1-888-992-4657
Europe, Africa, Middle East Tel: +44 (0)1202 571 111
India marketingroa@binks.com
China Tel: +8621-3373 0108
Korea Tel: +82313663303
Japan Tel: +81 45 785 6421
Australia Tel: +61 (0) 2 8525 7555
WARRANTY PAGE
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Binks®, DeVilbiss®, and Ransburg® are registered trademarks of Binks US, LLC.
© 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.
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