- BINKS - Smart Pumps E4-60 - Service Manual - 77-3229 [ English ]
77-3229
E4-60
Electric Drive Pump
107070 - (EU Model)
107072 - (Japan Model)
107073 - (USA Model)
104280 - (China Model)
EN
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
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
77-3229 R6.2 (04/2025) 2/40 www.binks.com
EN
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)
Lodging of ATEX Technical file
Signed for and on behalf of Binks
U.K. Ltd:
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 Declaration of Conformity / Incorporation is issued
under the sole responsibility of the manufacturer:
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
F. A. Sutter
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
EU Declaration of Conformity
Document Part No.
.
This Declaration of Conformity / Incorporation is issued under the sole responsibility of the
manufacturer:
77-3229 R6.2 (04/2025) 3/40 www.binks.com
EN
Binks U.K. Limited,
Ringwood Road,
Bournemouth, BH11 9LH. UK
Signed for and on behalf of Binks
U.K. Ltd:
Document Part No.
.
UKCA Declaration of Conformity
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.
F. A. Sutter 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:
Product Description / Object of Declaration:
This Product is designed for use with: Solvent & Waterbased Materials
Element Materials Technology Warwick Ltd. UK. (0891)
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)
Approved body details and role:
Lodging of UKEX Technical file
This Declaration of Conformity / Incorporation is issued
under the sole responsibility of the manufacturer:
77-3229 R6.2 (04/2025) 4/40 www.binks.com
EN
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.
Read the following warnings before using this equipment.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE
OPERATOR OF THE EQUIPMENT.
In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as
follows:
KEEP EQUIPMENT GUARDS IN PLACE.
Do not operate the equipment if the
safety devices have been removed.
PINCH POINT HAZARD. Moving parts
can crush and cut. Pinch points are
any areas where ther are moving
parts.
PROP 65 WARNING. WARNING: This product contains chemicals
known to the state of California to cause cancer and birth defects or
other reproductive harm.
WARNING
NOTE
KNOW WHERE AND HOW TO SHUT
OFF THE EQUIPMENT IN CASE OF AN
EMERGENCY.
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.
WARNING CAUTION
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.
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.
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.
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.
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.
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EN
1.50 l [0.40 US gal]
e.g. E4-60 Maximum Set Pressure of 18 bar to operate Pump on a 24/7 basis
SPECIFICATION
Fluid Output @ 80 HZ [40 cycles/min]:
Class 1, Group D.
Reduce Maximum working pressure by 2 bar [29 psi] when using in Open Loop Flow Mode
460V 3PH 5hp @ 60HZ
Gearbox Oil (EU Model):
Gearbox Oil (USA Model):
Total Weight of Pump (inc electric motor):
Rated 20 to 80 Hz (c/w thermisters)
EEx d 11B T3
355kg [737lbs]
Gearbox Ratio: 61.07:1 (EU MODEL)
AC Induction Electric Motor- EU Model :
Synthetic 220 (typically Agip Blasia S)
Max. Inlet Pressure:
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)
NOTE
E4-60* Maximum fluid pressure:
E4-60 Nominal flow volume / cycle:
Nominal pump stroke: 50mm [1.97 ins]
20 bar [290psi]
AC Induction Electric Motor - USA Model:
2'' Sanitary
SHC 630 Synthetic Oil
* Pressure when used in 'Smart Mode' (Closed Loop Pressure Mode)
Fluid Output @ 20 HZ [10 cycles/min]:
60 l/m [16.0 US gal/m]
2 bar [29 psi]
Fluid outlet connection:
'A'
'B'
Fluid inlet connection:
15 l/m [4.0 US gal/m]
77-3229 R6.2 (04/2025) 6/40 www.binks.com
EN
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.
DIMENSIONS AND MOUNTING DETAILS
B
A
1
3
8
8
-
1
6
5
0
77-3229 R6.2 (04/2025) 7/40 www.binks.com
EN
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
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].
The Pressure Switch is classified as simple apparatus and as such should be electrically connected as part of an
intrinsically safe electrical circuit.
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:
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 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.
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.
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EN
INSTALLATION
Inverter
Required Inverter Settings
Maximum Hz Output
Mininmum Hz Output
Acceleration Ramp
Deceleration Ramp
Rated Motor Power
Rated Motor Current
Rated Motor Power Factor
Rated Motor Efficiency
Rated Motor Frequency
Rated Motor Voltage
Rated Motor Speed
Value
80 Hz
20 Hz
5 Seconds
0.1 Seconds
3.0 kW
6.7 A
0.81
80%
50 Hz
400 V
1440 RPM
it must be connected to a suitable releasing device mounted within the control panel and wired to stop the motor
if an over temperature occurs.
Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into
consideration.
Once operating temperature is reached, this device quickly changes the resistance;
The motor is fitted with PTC temperature sensors (Thermistors).
Only trained personnel familiar with these standards should handle this type of apparatus.
Electric Motor
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.
If improperly used, badly connected, or altered no matter how minor, their reliability could be in doubt.
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EN
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INSTALLATION
Ensure the gearbox is filled with oil. (The gearbox is filled with the correct amount of oil at the factory.)
Suction - Ø50 I.D. [-1 to 10 bar working pressure]
Outlet - Ø38 - 50 I.D. [20 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.
e.g.,
Ensure adequate air space around the Pump for maintenance and electric motor cooling requirements.
Attach suitable flexible hoses to the inlet and outlet connections.
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EN
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SYSTEM OPERATION
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.
All required interlocks are tested and operational.
Suitable material for pumping is available at the suction hose.
Ensure all electrical and mechanical connections are correctly made.
Before starting:-
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.
The outlet connection is not blocked or isolated by any valves.
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EN
NOTE:
3.0KW ATEX MOTOR & ATEX
GEARBOX
1
4
164470
H083 GEARBOX (Not Shown)
ATEX GEARBOX (Not Shown)
5hp ELECTRIC MOTOR (Not Shown)
5hp ELECTRIC MOTOR (Not Shown)
3
9
2
194908
MANIFOLD WITHOUT PRV (Not
Shown)
1
USA MODEL-
107073-***
1
1651376
EU MODEL,
JAPAN MODEL,
USA MODEL
China Model-
107073-PRV-***
M12 x 40 HEX HEAD CAP SCREW
M12 WASHER
193116 1
USA MODEL-
107073-3**
107073-PRV-3**
194251
4
M12 SPRING WASHER (ST ST)
4 164469
4
8 194561 COVER C/W CAP FIXINGS
2
5
1 193711 1E4-60 MECHANICAL ASSY
PART NUMBER REMARKS
PARTS LIST - Pump Assembly
MANIFOLD & PRV ASSEMBLY194942
FLUID SECTION
ITEM QTYDESCRIPTION
USA MODEL-
107073-*1*
107073-PRV-*1*
7
EU MODEL
192687
JAPAN MODEL1194946
USA MODEL-
107073-1**
107073-PRV-1**
1192685
194921
1
2
China Model1
3.0KW ATEX/CCC MOTOR & ATEX
GEARBOX
172606
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.
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EN
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
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EN
DESCRIPTION
INLET MANIFOLD 1
1
5
3
4
5
192544
192635
192636
2'' SANITARY CLAMP
INLET MANIFOLD
ITEM PART NUMBER
8
1926353
QTY
4 192636 OUTLET MANIFOLD
1 192029 2'' SANITARY GASKET
41927916
OUTLET MANIFOLD
2'' SANITARY GASKET
2'' 90° STANDARD ELBOW
2
12
1
1
192791 2'' 90° STANDARD ELBOW 2
6 192792 2'' 90° EXT. SANITARY ELBOW 2
194930
2 192544 2'' SANITARY CLAMP
2'' 90° EXT. SANITARY ELBOW
2'' 90° EXT. SANITARY ELBOW
ITEM
12
11949318
1
192029
DESCRIPTION QTY REMARKS
PRESSURE RELIEF VALVE - 22 Bar104253-E4 1
PART NUMBER REMARKS
8
7
1
PARTS LIST - PRV and Manifold Assembly
PARTS LIST - MANIFOLD WITHOUT PRV
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EN
PRV and Manifold Assembly
MANIFOLD WITHOUT PRV
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
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EN
36
11
17
2
5
7
22
19
26
10
8
15
12
13
32
33
16
21
18
29
27
28
20
24
1
4
4
4
165100
165552
165588
165592
165660
165663
163161
163952
164469
164470
1
9
1
4
14
3
6
1
4
1
MOUNTING FRAME
BALL BEARING
ROLLER BEARING
LINEAR BEARING ROD
30
35
37
38
31
25
23
34
8
12
4
4
4
12
6
16
4
24
8
8
2
2
2
8
2
1
165671
165958
165959
192400
192441
5
2
1
1
2
1
192616
192617
192634
192639
192640
192643
192644
192645
192653
192654
192655
PARTS LIST - Mechanical Assembly
ITEM QTY REMARKS
1
4
1
1
8
1
�
�
�
�
192602
1/8 x 45° GREASE NIPPLE192650
Ø12 x 30 DOWEL PIN
14 x 9 x 50 KEY
M45 BEARING LOCKNUT
165044
165087
GREASE HOSE192662
192656
192661
192668
192682
192721
PART
NUMBER
M8 AEROTIGHT NUT
M6 x 20 SCREW
M12 x 40 SCREW
M12 WASHER
M12 SPRING WASHER
M6 SPRING WASHER
M16 SPRING WASHER
M8 x 20 SCREW
M16 x 30 SCREW
M16 x 50 SCREW
M8 x 16 GRUB SCREW
M8 x 30 GRUB SCREW
M10 x 20 GRUB SCREW
M6 x 20 SCREW (BRASS)
M6 WASHER (BRASS)
SPRING RETAINING WASHER
M16 EYE BOLT
SIDE PLATE
BEARING CAP
BEARING CLAMP
192603
DESCRIPTION
Ø58 X Ø80 X 8 SEAL
Ø100 x 2.5 O-RING
M50 BEARING LOCKNUT
1/8'' - 6mm ELBOW
SHAFT CLAMP ASSY
CARRIAGE ASSEMBLY
DRIVE SHAFT COUPLING
TOP PLATE MACHINED192601
BASE PLATE MACHINED
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EN
44
4
8
8
1
39 2
REMARKS
1
46
45
43
42
41
40
Parts list continued.
ITEM QTY
8
1
** Tighten bolts holding carriage ends once pump is fully assembled.
192752
193102
193104
193105
193697
194510
194540
PART
NUMBER
192817
1/4'' - 10mm ELBOW
CARRIAGE SPRING ROD
CARRIAGE SPRING
SPRING KEEP ASSEMBLY
SHAFT COUPLING SPACER
E4-60 SHAFT ASSEMBLY
SPACER
DESCRIPTION
E4-60 LEAK DETECTION HOSE ASSY
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
**
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EN
5
REMARKSITEM
20M10 x 70 CAP HEAD SCREW
PART NUMBER DESCRIPTION QTY
192600 CONSTANT VELOCITY CAM 2
1
3
4
192604
192605
192606
MIDDLE SHAFT
TOP SHAFT
BASE SHAFT
1
1
1
2
165571
PARTS LIST - Shaft Assembly
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
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EN
1 3 6
1
2
3
4
5
6
Assembly Tool
CAM Radial pitch offset
Fit top shaft, align holes and screw M10 x 20 cap head screws in using loctite 243 and tighten to 65Nm.
Place the second CAM (with 'TOP' engraving facing up), ensure the CAM is 3 holes radially out of pitch
from the first CAM.
Lift the assembly off of the assembly tool, rotate assembly and place back onto tool to complete
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.
Place CAM onto middle shaft with 'Top' engraving facing DOWN against middle shaft.
Hold assembly tool (502512) in a vice (flats provided) and install middle shaft.
Shaft Assembly
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EN
19266117
FOLLOWER GUARD WASHER1926115
1FOLLOWER NUT WASHER1926127
PART NUMBER
M8 x 20 CAP HEAD SCREW
1
4
6
DESCRIPTION
1
2LINEAR BEARING SPACER192615
1
ITEM
1
2
1
1
1
QTY REMARKS
4
6
8
3
19265211
16
1
Ø47 INTERNAL CIRCLIP
1/8'' x 6mm PUSH IN ELBOW
1/8'' GREASE NIPPLE / SLIP ON
M8 x 25 CAP HEAD SCREW
LEFT HAND CARRIAGE END
CARRIAGE MIDDLE
RIGHT HAND CARRIAGE END
CARRIAGE ADAPTOR
CAM FOLLOWER PIN
Ø72 CAM FOLLOWER
9
12
15
192608
192607
192609
192618
192610
2
192641
192642
165108
163152
192649
LINEAR BEARING
M8 SPRING WASHER
10
6
2
2
13
16555214
4
1
M16 NYLOC NUT
165553
PARTS LIST - Carriage Assembly
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EN
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
Bolts remain loose, tightened
when mechanical assembly is
complete.
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.
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EN
❷
Ø41 x 1.78 O-RING - PTFE
1
2
1
OUTLET CAP
22
❶❷
❶❷
165960
419255110
M6 SPRING WASHER 8
M8 SPRING WASHER
BALL CHECK SPRING160513
11 192620
3
4
5
165044
165087
❷2
1925059
19
1/4'' BSP HEXAGON PLUG
Ø12.42 x 1.78 O-RING
Ø1 3/8'' BALL
2
17
2
194243
2194237
2192648
OUTLET CYLINDER 1
OUTLET BLOCK
2
PISTON ASSEMBLY 2
PART NUMBER DESCRIPTION QTY REMARKS
165957
INLET CYLINDER 1
❶❷
16
2SEAT
2
21
7
ITEM
8
14 192625
192626 OUTLET CAGE
12 192621
13 192624
4
165108
171788
❶❷
8
M6 x 25 CAP HEAD SCREW
❶❷
M12 x 40 CAP HEAD SCREW
M8 x 90 CAP HEAD SCREW
8163921
6 8
M12 SPRING WASHER 16
2OUTLET SPRING KEEP192630
PISTON SEAL
19267920
192632
16
15
SHAFT/BELLOWS ASSY
18 192647 Ø50.5 x 2.62 O-RING - PTFE 4 ❶❷
�
PARTS LIST - Fluid Section
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EN
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
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EN
193627
REMARKS
��
PISTON BALL CHECK SPRING ��
Ø82.22 x 2.62 O-RING
1628052
1
PART NUMBER
1 160513
��1
Ø50.52 x 1.78 O-RING
Ø63.17 x 2.62 O-RING
QTY
9
1
DESCRIPTION
1
Use a 32mm Single Hex
Socket when tightening or
removing ball cage
from Piston.
5 171784 Ø1.75'' BALL 1
7 192631 SEAT 1
8 193626
1
Ø100 FLUID PISTON
��
1 ��4
1926296
��1628073
BALL CAGE
1
�
�
ITEM
INLET SPRING KEEP
162854
PARTS LIST - Piston Assembly
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
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EN
BELLOWS POSITIONING TOOL
ITEM
RETAINING NUT
PART NUMBER
PISTON SHAFT
TOOL
1
QTY
2
DESCRIPTION
��
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).
REMARKS
6 502377
192619
1
1
1
1
1
Using Item No. 6, push bellows
over spigot until located in groove.
KNIFED BELLOWS
192374
192579
192627
192628
��
7 502382 BELLOWS ASSEMBLY SPIGOT
3
SHAFT SEAL
TOOL
4
5
BELLOWS SPACER
PARTS LIST - Shaft & Bellows Assembly
KEY
(Reverse for assembly)
LOCTITE
TORQUE
MAINTENANCE ORDER
GREASE INTERNAL
(AGMD-010)
GREASE
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EN
•
•
• Fluid Pressure Output Requirement
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 ;
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.
The two components which are more greatly affected by the above criteria than any other components in the
pump are:
Abrasiveness of Fluid Pumped
Pump Duty Cycle
Maintenance
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EN
Weekly
Check for any excessive mechanical noise
Annually
6 Monthly
Inspect Piston and Replace Piston Seals / Bellows / Springs.
Every 5 Years
Use only 502375 (KP2N-20 DIN 51825) Grease for Cam Follower Bearing.
Stop the pump and apply (502376) grease to linear bearings, 6 strokes of a
standard ‘cartridge’ grease gun (502514).
Inspect Cam and Cam followers for excessive wear, replace if excessive wear can
be seen.
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.
Inspect Piston & Outlet Ball Checks, replace as necessary.
Inspect Linear Guide Bearing and Guide Rails for excessive wear.
Maintenance schedule
Daily Check for any fluid leakage
Check for excessive fluid pressure pulsation
Replace main shaft bearings. Linear Guide Bearings, Guide Rails and Cams if
excessive wear can be seen.
Check oil level within gearbox
3 Monthly
While running, apply (502375) grease to cam follower bearings, 8 strokes of a
standard ‘cartridge’ grease gun (502373).
Inspection Operation
Maintenance
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EN
Wait until the unit has cooled sufficiently after stopping and isolation.
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.
Gearbox
Every 1000 hours verify the good condition of oil seals and gaskets
The unit must be removed to be drained, maintained and filled with oil.
After filling with fresh oil, refit the level and/or drain plugs and clean up any oil spillage.
Maintenance
Note:
WARNING
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.
Maintenance - Gearbox
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EN
•
•
•
•
•
•
•
•
•
WARNING
Factory equipment with tooling and facilities, suitable to make repairs.
Quality control department, for the checks and the tests, requested after repairs.
Maintenance of Ex Motors - are reported by EN 60079-17 standard, in particular:-
The insulation air-distance and the surface-distance between conductors, required by the standards, must
be respected.
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 from the manufacturer.
The join surfaces have just to be cleaned and, in order to avoid corrosion or water entrance.
Wait until the unit has cooled sufficiently after stopping and isolation.
The electric connections must be correctly locked to avoid resistance-increases, with consequent contact
overheating.
For the Ex motors the repairs of parts, directly involved on the protection against the explosion risk, must
be done without any modification to the original motor design.
Electric Motors
All the screws, used to assemble the parts of the motors and of the terminal box, must be completely
tightened.
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:
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.
Maintenance - Motor
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EN
Grease bearing or replace if damage
is too great
Mechanics
Symptom Possible Cause Remedy
Drive between shafts in the gear unit
interrupted
Return the unit for repair and replace
gearbox
b) Fluid seal friction or piston
movement prevented
a) Spring tension insufficient
c) Replace inner coupling spider..
Check both coupling hub locking
screws are tightened to specified
torque.
Carriage does not maintain contact
with cam; Noisy Changeover
c) Loose or worn drive shaft coupling
• from the motor flange
c) Check vent is clean/fitted and not
the transportation plug
b) Return gearbox
Gearbox Oil leaking
a) Defective gasket on gear unit
cover.
b) Check fluid section
Bearing needs lubrication
Cam Followers bearing generating
heat / noise
• from the output oil seal
• from the gear unit flange
a) Retighten screws on gear unit
cover.
Gearbox Output shaft does not
rotate, even though the motor is
running.
c) Gear unit not ventilated
b) Defective gasket.
• from the gear unit cover
Gearbox Oil leaking from ventilator Unit overfilled with oil. Check and correct the oil level
a) Check and replace springs
Fault Finding
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EN
a) Replace piston seals.
b) Inverter Unit or safety interlocks
‘tripped’
b) Inspect, clean/replace balls/seats
b) Worn piston seals
c) Inspect, clean/replace balls/seats
Fluid Section
Symptom Possible Cause
b) Replace piston seals.
a) Check o-rings and hose
connections
b) Main shaft bearings worn
a) Ball checks not seating correctly.
Pump will not ‘Prime’
d) Cam direction incorrect
c) Cam profile worn down
Replace bellows seal, check piston
seal, replace as necessary
Excessive Pressure Pulsation
Remedy
Paint leaking from inside cover
Pump will not run
Pump runs, but lack of pressure
b) Worn balls and / or seats
a) Worn piston seals
b) Inspect, clean and/or replace
main bearings
a) Inspect, clean/replace balls/seats
Bellows seal failure
c) Replace cam
d) Remove shaft assembly and
rebuild with correct cam orientation
c) Ball checks not seating correctly.
a) Air entering the suction
hose/manifold
a) No power
b) Check inverter and fault
conditions
a) Check electrical supply
Fault Finding
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EN
1
2
3
4
5
6
7
9
Check for any leaks and mechanical noises.
While running, apply (502375) grease to cam follower bearings, 8 strokes of a standard ‘cartridge’ grease
gun (502373).
8 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).
Testing and Lubricating after major overhaul
WARNING
Allow the pump to run for about 10 minutes between 60 to 80Hz to ensure any trapped air is correctly
vented.
Run the pump at 20 cycles/min [50 HZ] and increase the back pressure to 10 bar and run for 1 hour.
The pump will now have most of the paint removed;
3
Testing and Lubricating - Qualified personnel only
Check for any leaks and mechanical noises.
Fluid Drain Down
Connect electric motor to a suitable electrical supply.
Fit the gearbox vent plug.
Turn on paint system and set back pressure regulator to zero.
Turn the pump on at the local isolation mounted switch.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent
manufacturer.
1 Stop the pump (turn off the electric motor);
isolate the paint supply and place a suitable container underneath the hose to prevent spillage.
2 Disconnect the inlet & outlet hoses and position securely into a suitable container.
Start the pump and run at slow speed [20Hz] for 1 minute.
however, some material will remain within the fluid cylinders and manifolds.
4 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.
Connect pump to paint system.
Testing and Lubricating
IMPORTANT
Never allow the pump to run with a closed (‘valved off’) inlet or outlet connection
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EN
*
*
# 192688 AUTO LUBRICATION KIT
Check Main Parts List for details of Individual Kit Contents
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 ensure a clockwise motion.
Fluid section seal & fluid section overhaul kits contain all the necessary components to service Mark one
and two pistons. Discard components not required.
# 193626 Ø 100 PISTON
# 502673 CAM UPGRADE KIT
Note:
250599
Recommended Replacement Spare Parts and Kits for E4-60 Pumps
KIT No. PART NUMBER DESCRIPTION
MAIN BEARING OVERHAUL KIT
250797 FLUID SECTION OVERHAUL KIT
250595 BELLOWS REPLACEMENT KIT
250597 CAM FOLLOWER BEARING KIT
REMARKS
� 250769 FLUID SECTION SEAL KIT
250598 LINEAR GUIDE AND ROD KIT
# 192600 CONSTANT VELOCITY CAM
Spare Parts List
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EN
502375
502373 GREASE GUN FOR CAM FOLLOWER (& MAIN BEARINGS)
502376 GREASE FOR LINEAR BEARINGS
COLLET CONNECTOR
502514 GREASE GUN FOR LINEAR BEARINGS (300mm EXTENSION) HOOK CONNECTOR
192547 [4 -20 mA / 0 - 25 bar] PRESSURE SENSOR
PRESSURE FEEDBACK
G½ MALE
PART NUMBER DESCRIPTION REMARKS
192569 SENSOR MANIFOLD
1x G½ FEMALE +
2x Rc⅜ (⅜ BSPT FEMALE)
192544 2.0'' SANITARY CLAMP
ACCESSORIES
2.0'' SANITARY GASKET
GREASE FOR CAM FOLLOWER (& MAIN BEARINGS)
PRESSURE SWITCH R⅜ (⅜ BSPT MALE)
192029
502144
192800 SMART CARD
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EN
502382 BELLOWS ASSEMBLY SPIGOT
BELLOWS ASSEMBLY TOOL
M8 TORX SECURITY SCREWDRIVER FOR COVER
502512 SHAFT ASSEMBLY TOOL
502934
502510 TOP BEARING PRESS TOOL
PISTON CAGE ASSEMBLY TOOL
502508
BOTTOM BEARING PRESS TOOL
PART NUMBER DESCRIPTION
502509 BOTTOM BEARING LOCKNUT TOOL
FOC with a New Pump
502508 TOP BEARING LOCKNUT TOOL
502511
REMARKS
192450
502377
ACCESSORIES
502934
502509
502510
502511
502512
502377 & 502382
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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.
● 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.
Gearbox Long Term Storage
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EN
NOTES
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EN
NOTES
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EN
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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EN
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.
© 2025 Binks US, LLC. All rights reserved.
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