Service Manual
EN
PumpMaple 15/6
104205• Model
77-3244 R1.0 1/20 www.carlisleft.com
Product Description / Object of Declaration:
This Product is designed for use with: Solvent and water based materials
Suitable for use in hazardous area: Zone 1
Protection Level: II 2 G X IIB T4
Notified body details and role: Element Materials Technology (0891)
This Declaration of conformity / incorporation
is issued under the sole responsibility of the
manufacturer:
Pumps - Maple, DVP, 104009, 104010, 104010-LS,
104016, 104027, 104032, 104040, 104041, 104042,
104077, 104020, 104023, 104025, 104028, 104129,
106933, 104205,
Lodging of Technical file
Carlisle Fluid Technologies UK Ltd,
Ringwood Road,
Bournemouth, BH11 9LH. UK
EN
EU Declaration of Conformity
The object of the declaration described above is in conformity with the relevant Union
harmonisation legislation:
Machinery Directive 2006/42/EC
ATEX Directive 2014/34/EU
by complying with the following statutory documents and harmonized standards:
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN 12621:+A1:2010 Machinery for the supply and circulation of coating materials under pressure - Safety
requirements
EN1127-1:2011 Explosive atmospheres - Explosion prevention - Basic concepts
EN 13463-1:2009 Non electrical equipment for use in potentially explosive atmospheres - Basic methods and
requirements
EN 13463-5:2011 Non electrical equipment for use in potentially explosive atmospheres - Protection by
constructional safety "c"
Providing all conditions of safe use / installation stated within the product manuals have been
complied with and also installed in accordance with any applicable local codes of practice.
Signed for and on behalf of Carlisle Fluid
Technologies UK Ltd:
D Smith
13/4/17
Director of Sales (EMEA)
Bournemouth,BH11 9LH,UK
77-3244 R1.0 2/20 www.carlisleft.com
In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as
g
follows:
EN
WARNING CAUTION
Hazards or unsafe practices which could result in
severe personal injury, death or substantial property
damage.
Read the following warnings before using this equipment.
READ THE MANUAL. Before operating finishing equipment, read and
understand all safety, operation and maintenance information
provided in the operation manual.
WEAR SAFETY GLASSES. Failure to wear safety glasses with side
shields could result in serious eye injury or blindness.
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.
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.
Hazards or unsafe practices which could result in
minor personal injury, product or property
damage
WARNING
NOTE
Important installation, operation or maintenance
information.
AUTOMATIC EQUIPMENT. Automatic
equipment may start suddenly without
warning.
PROJECTILE HAZARD. You may be
injured by venting liquids or gases that
are released under pressure, or flying
debris.
KNOW WHERE AND HOW TO SHUT
OFF THE EQUIPMENT IN CASE OF AN
EMERGENCY.
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.
EQUIPMENT MISUSE HAZARD. Equipment misuse can cause the
equipment to rupture, malfunction or start unexpectedly and result in
serious injury.
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.
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
and result in fire, explosion or elecrtic shock and other serious injury.
PROP 65 WARNING. WARNING:This product contains chemicals
known to the state of California to cause cancer and birth defects or
other reproductive harm.
rounding or sparks can cause a hazardous condition
OPERATOR TRAINING. All personnel
must be trained before operating
finishing equipment.
PACEMAKER WARNING. You are in the
presence of magnetic fields which may
interfere with the operation of certain
pacemakers.
KEEP EQUIPMENT GUARDS IN PLACE.
Do not operate the equipment if the
safety devices have been removed.
NEVER MODIFY THE EQUIPMENT. Do
not modify the equipment unless the
manufacturer provides written
approval.
PINCH POINT HAZARD. Moving parts
can crush and cut. Pinch points are
any areas where ther are moving
parts.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE
OPERATOR OF THE EQUIPMENT.
77-3244 R1.0 3/20 www.carlisleft.com
Specification
A
A
A
Ratio: 6:1
Maximum air inlet pressure: 7 bar [101.5 psi]
Maximum fluid pressure: 42 bar [610 psi]
Nominal flow volume / cycle: 0.375 l/m [0.10 US gal/m]
Output @ 60 cycles / min: 22.5 l/m [6 US gal/m]
EN
Maximum recommended continous cycle rate:
Cycles/min
Maximum recommended intermittent cycle rate:Cycles/min 40
Fluid inlet connection:
Fluid outlet connection:
Compressed Air Inlet 3/8" BSPP / NPSM
Air volume / cycle @ 3.1 bar/45psi:
Air volume / cycle @ 6.2 bar/90psi:
ir consumption @ 15 cycles/min and 6 bar [87 psi] air inlet
pressure:
ir consumption @ 30 cycles/min and 6 bar [87 psi] air inlet
pressure:
9.5 l/m [0.33 SCFM]
18.5 l/m [0.65 SCFM]
283 l/m [10 CFM]
566 l/m [20CFM]
Sanitary1"
Sanitary
1"
20
Max. Pump Fluid Inlet Pressure 2 bar [30 psi]
5 microns
Dirt:
Water:
Oil:
-20°C @ 7bar [940ppm]
0.1mg/m³
# Note:
ir Quality ISO 8573.1 Class 3.3.2
# See Note
Weight: 45.5 kg / 91 lbs
Class 3.4.2 Air Quality (Refrigerant dried - water +3ºC@7bar) may be used, however,
above 15 cycles/min optional heavy duty mufflers 192821 or piped exhaust system should
be used, if used continuously.
77-3244 R1.0 4/20 www.carlisleft.com
Dimensions and Mounting Details
1" Sanitary outlet
1" Sanitary inlet
EN
AIR INLET
EARTHING POINT
MOUNTING LOCATIONS
SECTION A-A
77-3244 R1.0 5/20 www.carlisleft.com
EN
Installation
This product should be flushed with a suitable compatible solvent prior to use.
Mount the pump securely and position the pump at a convenient height (below the lid height of the
paint container), to allow for maintenance, visual observation, and periodic inspection.
The wall mount bracket is included with all pumps.
The Pump Mounting bracket must be connected to a suitable earth ground to ensure that there is no
possibility of static build up.
Attach suitable flexible hoses to the inlet and outlet connections.
Connect a suitable 3/8" NB air hose and 1/2” Pressure Filter Regulator to the air motor.
(Filter rated at minimum 1000 l/min)
No additional air lubrication is required as piston ring lubricant is applied during assembly or repair.
If an air lubricator is used then this must be maintained.
77-3244 R1.0 6/20 www.carlisleft.com
Installation
Set the pump speed to a slow cycle rate and prime the pump to remove any air before increasing
pressure.
Inspect for any air or fluid leaks.
Set the pump cycle rate to achieve the required paint volume and then adjust the system back
pressure regulator and pump air pressure to achieve the desired system fluid pressure.
EN
A Back Pressure Regulator should be mounted in the paint system return line.
The return line ‘back pressure’ regulator responds to the changes in system fluid flow demand, (due to
variable paint usage) by dynamically adjusting the paint flow rate returning to the system paint tank,
thus maintaining the set pressure.
If an air blow out system is used, never exceed 2 bar [29 psi] on the inlet of the pump.
Exhaust kits are available for these pumps if the air exhaust is required to be piped away from the
pump rather than exhausting locally through the mufflers.
77-3244 R1.0 7/20 www.carlisleft.com
Parts list - Pump Assembly
EN
ITEM QTY REMARKS
1
2
3
4
5
6 8
7 1"
8
9 4
10
11 6
PART NO. DESCRIPTION
164838
165044
165108
177107
177109
177111
192206
192382
192505
192551
192712
Ø2 x 4.75
SPRING WASHER
M12 16
SPRING WASHER
M8 8
M12 x 50
M8 x 65 SOCKET HEAD CAP SCREW
M12 X 110 SOCKET HEAD CAP SCREW
SANITARY GASKET
BALL
1" 2
Ø12.42 x 1.78 O-RING
HEXAGON PLUG
1/4" 4
Ø37.82 x 1.78 O-RING
RIVET
SOCKET HEAD CAP SCREW
2
8
8
4
12
13
14
15
16
17
18
19
20 4
21
22
23
24
25 41-4404
192777
192816
192833
192835
193360
193775
194179
194242
194845
194971
194974
194976
194979
SILENCER
1" 2
LABEL
SEAT
OUTLET MANIFOLD
INLET MANIFOLD
LABEL
OUTLET FITTING
Ø70 2
AIR MOTOR ASSEMBLY
OUTLET CYLINDER
PISTON SEAL
INLET CYLINDER
BALL CAGE
PISTON ASSEMBLY
1 & 1 1/2
SANITARY CLAMP
1
2
1
1
1
2
1
2
2
#
2
2
77-3244 R1.0 8/20 www.carlisleft.com
Pump Assembly
EN
KEY
= GREASE
(AGMD-010)
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
77-3244 R1.0 9/20 www.carlisleft.com
Parts list - Air Motor Assembly
EN
ITEM PART NO. QTY REMARKS
1 0115-010037 POPPET ASSEMBLY
2 0115-010102 AIR VALVE ASSEMBLY
1619923 2
4
5 161994
6 161995 O-RING 2
7 162703 SHAFT SEAL
8 162704 SHAFT BEARING
9
10
11 165528 M4 x 16 SOCKET HEAD CAP SCREW
161993
163920 4M6 x 30 SOCKET HEAD CAP SCREW
165108
Ø117.5 x 2.62 O-RING
Ø20.35 x 1.78
Ø4.47 x 1.78
Ø19.5 x 3
M8 16
DESCRIPTION
O-RING
O-RING
SPRING WASHER
2
#
1
2
4
2
2
4
12 165963
16597013
16597114
15
16 192374
18 192757
19 192761 CYLINDER STUD
20
21 192763 BELLOWS SPACER
22 192764 PUMP BRACKET
23 192799 VENT PLUG
24 192812 EXHAUST ADAPTER
25 192814
27 194293
177038 M10 x 12 BUTTON HEAD CAP SCREW 4
RETAINING NUT
19257917
192762
KNIFED BELLOWS
AIR CYLINDER
CYLINDER STUD - LONG
BELLOWS LEAK
DETECTION HOSE
PUSH IN ELBOW19281526
AIR MOTOR PISTON
DOME NUT
M8 16
PLAIN WASHER
M4 4
SPRING WASHER
M4 4
2
2
#
1
6
2
2
2
2
1
1
2
1
28 194972 END PLATE MACHINING 2
77-3244 R1.0 10/20 www.carlisleft.com
KEY
EN
ITEM 7
DETAIL
(AGMD-010)
(AGMD-010)
= LOCTITE
= GREASE
= TORQUE
(Reverse for assembly)
= GREASE INTERNAL
= MAINTENANCE ORDER
77-3244 R1.0 11/20 www.carlisleft.com
Air Motor Piston Assembly
EN
ITEM PART NO. DESCRIPTION QTY
1627021
AIR MOTOR PISTON SEAL 1
GRUB SCREW 1165964 M12 x 402
3 192759 PISTON SHAFT
4 192760 PISTON
2
1
REMARKS
KEY
= GREASE
(AGMD-010)
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
77-3244 R1.0 12/20 www.carlisleft.com
Air Valve Assembly
EN
ITEM PART NO. DESCRIPTION
1 0115-010015
162789 6
2 0115-010016
3 0115-010017
4 0115-010018
5 0115-010020
6 0115-010021
7 0115-010049
8 0115-010073
9 0115-010097
10 0115-010103
11 0115-010107
12 180584
19281313
SPOOL AND SLEEVE ASSEMBLY
SPOOL AND SLEEVE O-RING
BUMPER
MAGNET
VALVE BLOCK END CAP
DIAPHRAGM
Ø36 x 1.5 O-RING
Ø20 x 2 O-RING
M4 x 12 BUTTON HEAD CAP SCREW
VALVE BLOCK.
1/4 BSPT PIPE PLUG
1/8 BSPT PIPE PLUG
3/8"
QUICK EXHAUST VALVE CAGE
UNIVERSAL FITTING
QTY REMARKS
1
#
Not Shown
2
2
2
2
2
2
8
1
1
1
1
2
KEY
= GREASE
(AGMD-010)
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
= MAGNET HAZARD
77-3244 R1.0 13/20 www.carlisleft.com
Fluid Piston Assembly
ITEM PART NO. DESCRIPTION QTY REMARKS
EN
1605331
2 162855
3 162856
4 162857
5 171788
6 192632
7 193188
8 194111
9 194113
PISTON BALL CHECK SPRING
Ø52.07 x 2.62 O-RING
Ø41.0 x 1.78 O-RING
Ø56.82 x 2.62 1
1.375 1
SEAT
INLET SPRING KEEP
Ø70 1
BALL CAGE
BALL
FLUID PISTON
O-RING
Use a 25mm Single Hex
Socket when tightening or
removing ball cage
from Piston.
1
1
1
1
1
1
KEY
= GREASE
(AGMD-010)
= LOCTITE
= TORQUE
= MAINTENANCE ORDER
(Reverse for assembly)
= GREASE INTERNAL
(AGMD-010)
77-3244 R1.0 14/20 www.carlisleft.com
Fault Finding
Symptom Possible Cause Remedy
EN
Pump will not ‘Prime’
Air getting into the suction hose/manifold
Worn piston seal. Replace piston seals.
Ball checks not seating correctly.
No Air or Fluid supply
Air piston seal worn. Replace piston seal.
Pilot valve assemblies inoperable.
Check seals and hose connections.
Inspect, clean and/or replace balls
and seats.
Check air and fluid supply ball valves
and supply hoses.
Switch/interchange pilot valves to
isolate faulty pilot valve and
clean/replace.
Pump will not run
Pump runs but has
excessive pulsation.
Pilot valve assemblies inoperable. Check clean/replace Air valve.
Check for constant exhaust air when
QE diaphragm defective.
Ball checks not seating correctly.
Air getting into fluid line, air supply restricted. Check seals and hose connections.
Obstructed fluid ball checks.
pump is not running. Check/replace
QE diaphragms.
Inspect, clean and/or replace balls
and seats.
Check air supply
Remove, clean, and inspect seat,
ball, and ball cage. Replace if
suspect or worn.
77-3244 R1.0 15/20 www.carlisleft.com
Fault Finding
Symptom Possible Cause Remedy
Worn air motor piston seals. Replace air motor piston seal.
EN
Pump runs but has
excessive pulsation.
Paint leaking into
detection hose, Air
bleeding from vent
plug
Worn/failed air motor shaft seals.
Worn fluid piston seal. Replace fluid piston seal.
Air exhaust restricted.
Bellows seal failure Replace bellows seal
Air motor shaft seal leaking
Disassemble pump as required to
replace air motor shaft seals.
Check QE diaphragms and exhaust
outlets.
Check air motor shaft seal replace as
necessary
77-3244 R1.0 16/20 www.carlisleft.com
Spares Kits for Maple 15/6 Pump
KIT No. PART NO. DESCRIPTION QTY REMARKS
EN
# 0115-010037
# 0115-010015
# 194976
# 192579
Recommended spare parts for continually running pumps
# -
250771
250772
250618
250628
Fluid section seal kit
Fluid overhaul kit
Air Motor Seal Kit
Control Valve Kit
Poppet Assembly
Main Spool & Sleeve Valve Assembly
Piston seal
Knifed Bellows
Maintenance schedule
Inspection Operation
Daily Check for any general fluid or air leakage.
1
Check main parts list for
1
1
1
1
1
1
1
details of individual kit
2 off per pump
1 off per pump
2 off per pump
2 off per pump
contents
Weekly
6 Month Test
12 to 36 Months (Typically 10
million pump cycles
dependant on air quality and
abrasiveness of the paint
used)
Inspect Pump for Correct operation
Check for any excessive mechanical noise
Check for excessive fluid pressure pulsation
Perform a pump stall test to ensure correct operation.
If pump does not stall check fluid piston seals and ball checks, replace as required.
If air is escaping through exhaust check air motor piston seal and quick exhaust
diaphragm, replace as required.
Replace air piston seal,
Replace shaft seals & bearings.
Inspect and replace if required: Pilot Air Valves & Main Air Valve Parts.
Replace fluid piston seal,
Replace Balls,Seats and Bellows.
77-3244 R1.0 17/20 www.carlisleft.com
Bellows Replacement
ITEM PART NO. DESCRIPTION QTY REMARKS
1 502769 Bellows positioning tool 1
EN
2
502382 Bellows assembly spigot
1
12
Screw Item No. 2 (assembly spigot)
onto the piston shaft
Using Item No. 1, push bellows
over spigot until located in groove.
Smear loctite 572 over nose of bellows,
thread nut onto bellows ensuring the
thread starts squarely. Grip bellows
lightly by hand and tighten the nut with
a 1" A/F spanner until the nut contacts
the bellows shoulder.
77-3244 R1.0 18/20 www.carlisleft.com
(f)
Accessories
ITEM PART NO. QTY
EN
192206
193275
194845
194281
502608
502769
AGMD-010
192779
192803
192821
1" Sanitary Gasket
1"
Sanitary -
3/4" NPT (f) Adapter
1 & 1 1/2"
1" NPT
Seal Insertion Tool
Bellows Positioning Tool
Kluber Isoflex Topas NB 52 Grease 50ml Tube
Exhaust Tube Adapter (1” NB hose) For piped exhaust
1" Manifold Plug For piped exhaust
1" BSP Heavy Duty Mufflers
Heavy duty
Sanitary Clamp
Sanitary -
1"
Adapter
For Shaft seal (7)
Recommended for high pump pressures
and cycle rates
192820
502382
Exhaust Tube Adapter (1.25” NB hose)
Bellows assembly spigot
For piped exhaust
77-3244 R1.0 19/20 www.carlisleft.com
EN
WARRANTY POLICY
Binks products are covered by Carlisle Fluid Technologies five year materials and workmanship
limited warranty. The use of any parts or accessories, from a source other than Carlisle Fluid
Technologies, will void all warranties. For specific warranty information please contact the
closest Carlisle Fluid Technologies location listed below.
Carlisle Fluid Technologies reserves the right to modify equipment specifications without prior notice.
DeVilbiss®, Ransburg®, MS®, BGK® and Binks® are registered trademarks of Carlisle Fluid
Technologies, Inc.
© 2017 Carlisle Fluid Technologies, Inc.
All rights reserved.
Binks is part of Carlisle Fluid Technologies, a global leader in innovative finishing technologies. For
technical assistance or to locate an authorized distributer, contact one of our international sales and
customer support locations below.
USA/Canada Mexico
www.binks.com
info@carlisleft.com
Toll Free Tel: 1-888-992-4657
Toll Free Fax: 1-888-246-5732
United Kingdom France Germany
www.carlisleft.eu
info@carlisleft.eu
Tel: +44 (0)1202 571 111
Fax: +44 (0)1202 573 488
China Japan Australia
www.carlisleft.com.cn
mkt@carlisleft.com.cn
Tel: +8621-3373 0108
Fax: +8621-3373 0308
www.carlisleft.com.mx
ventas@carlisleft.com.mx
Tel: 011 52 55 5321 2300
Fax: 011 52 55 5310 4790
www.carlisleft.eu
info@carlisleft.eu
Tel: +33(0)475 75 27 00
Fax: +33(0)475 75 27 59
www.ransburg.co.jp
overseas-sales@carlisleft.co.jp
Tel: 081 45 785 6421
Fax: 081 45 785 6517
Brazil
www.devilbiss.com.br
vendas@carlisleft.com.br
Tel: +55 11 5641 2776
Fax: +55 11 5641 1256
www.carlisleft.eu
info@carlisleft.eu
Tel: +49 (0) 6074 403 1
Fax: +49 (0) 6074 403 281
www.carlisleft.com.au
sales@carlisleft.com.au
Tel: +61 (0) 2 8525 7555
Fax: +61 (0) 2 8525 7575
77-3244 R1.0 20/20 www.carlisleft.com
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