Pompa BINKS MAPLE 15
|High Quality materials and surface treatments are used in the construction of this pump to ensure both extended operational life and good future appearance. The Maple pump is a horizontal piston pump for pumping Solvent / Waterborne Paints, Solvents and other suitable materials. An Ø125 x 50mm stroke air motor is used to drive two fluid sections giving a combined output of 0.375 L per cycle. The unit combines an energy efficient air motor with low shear fluid section technology from the range of Smart Electric Pumps. The Maple Pump achieves a reciprocating drive by using high technology ground and lapped steel spool and sleeve air valves to control the air motor reversal, providing reciprocating motion. The air valve design (patent pending) ensures a positive magnetic detent for the main and pilot air valves thus removing the possibility for a stall condition. The air motor also utilises the Binks Low Ice quick exhaust technology to prevent air valve freezing conditions when high cycle speeds are employed. Equal thrust on each stroke due to the horizontal configuration incorporating the dual piston rod design gives a balanced fluid pressure output and reduces fluid pressure fluctuations to a minimum. The air pump is furnished with twin exhaust mufflers to control exhaust noise emission. An adapter kit is available to facilitate connection to a piped exhaust system if required. A 1/8” Port is incorporated into the main air valve to facilitate an optional cycle counter. Complies with current relevant European and US Legislation.|
The Assembly comprises of:
• Central Air Piston and ‘change over’ Valves
• 2 off Quick Exhaust and muffler assembly
• 2 off Dynamic Chambers and Fluid Pistons
• 2 off Fluid Pressure Chambers each complete with Suction and Pressure Ball Check Valve Assemblies
• 1 off Fluid Inlet Manifold
• 1 off Fluid Outlet Manifold
• Support Bracket
|Dimensions and Mounting Details|
|Important Safety Information|
|Fire, Explosion and Electric Shock Hazard
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire, explosion, or electric shock. When installed and operated in accordance with its instructions, the pump is approved for operation in Zone 1 (Europe) & Division 1 (North America), hazardous locations. (ATEX Cat 2)
• Electrical equipment must be installed, operated, and serviced only by trained, qualified personnel who fully understand the requirements stated in this instruction manual.
• Ground the equipment and all other electrically conductive objects in the spray area. After grounding test with ohmmeter to ensure earth continuity is 1 ohm or less.
• Keep all covers tight while the motor is energized.
• If there is any static sparking or you feel an electric shock while using this equipment, stop spraying/dispensing immediately. Do not use the equipment until you identify and correct the problem.
• Provide fresh air ventilation to avoid the build up of flammable fumes from solvents or the fluid being pumped.
• Keep the pumping area free of debris, including solvent, rags, and gasoline.
• Electrically disconnect all equipment in the pumping area.
• Extinguish all open flames or pilot lights in the spray/dispense area.
• Do not smoke in the spray/dispense area.
• Do not turn on or off any light switch in the spray/dispense area while operating or if fumes are present.
• Do not operate a gasoline engine in the spray/dispense area.
Hot Surface Hazard
• The electric motor becomes hot during operation, and the heat may be transferred to other connected equipment. To reduce the risk of burning yourself, do not touch the motor surfaces while it is operating. Before servicing, allow the motor to cool.
• Keep flammable materials and debris away from the equipment.
Pressurized Equipment Hazard
Spray from the gun/valve, hose leaks, or ruptured components can splash fluid in the eyes or on the skin and cause serious injury.
• Do not point the gun/valve at anyone or at any part of the body.
• Do not stop or deflect leaks with your hand, body, glove or rag.
• Spraying/dispensing; clean, check, or service the equipment.
• Tighten all fluid connections before operating the equipment.
• Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately. Permanently coupled hoses cannot be repaired; replace the entire hose.
Toxic Fluid Hazard
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.
• Know the specific hazards of the fluid you are using.
• Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.
• Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer. Moving Parts Hazard
• Keep clear of all moving parts when starting or operating the pump.
|Air Motor Assembly|
|0115-010102 Main Air Valve Assembly|
|Pump Assembly – Air Motor|
Ensure all parts are clean and degreased.
1. Push bearings (10) into end plates (24) and insert ‘O’ rings (4) into the large grooves, applying a light coating of grease type #.
2. Apply light coating of grease type # to the seal groove of the piston and insert the ‘O’ ring portion of the piston seal (8), apply a little more grease to the top of the ‘O’ ring. Carefully fit the seal strip into the piston groove (fit one half of the seal into the groove and then apply pressure to the o-ring seal already in the groove, and pull the remaining seal into the groove, being careful to avoid unduly stretching the seal strip).
3. Insert grub screw (16) into one of the piston shafts (25) use Loctite studlock 2701 and tighten to 45Nm. Mount this through the piston (26) and screw on the other shaft (25) again using loctite studlock 2701 and tighten to 100Nm. Clean off any residue of loctite.
4. Lightly apply grease type # to the inside of the air motor cylinder (23), insert the piston and shaft sub-assembly into the cylinder at a 45° angle and turn the piston until it is inline with the cylinder.
5. Insert the cylinder end plate sub-assemblies over lightly greased # shafts and into the cylinder. Press parts lightly together, making sure that the Main Valve (3) mounting surfaces are inline.
|6. Insert 4 off M12 Cap Head Screws (15) and spring washers (27) into each cylinder end plate sub-assembly to secure the cylinder, tighten in ‘cross over’ sequence together to 40Nm.
7. Apply grease type # onto the shafts and gently push over the shaft seal (9), lips pointing inwards (Use Tool 502608), push the seal fully home into the end plate. Then fit the bellows retainer (28) over the shafts, smaller hole facing inwards.
8. Screw 502382 assembly spigot onto the piston shaft (25).Using tool 502377 push the bellows (21) over the assembly spigot until the bellows internal spigot locates into the shaft groove. (Using the tool prevents damage to the convolutions)
9. Smear a film of loctite 572 over the nose of the bellows then thread the nut (20) onto the bellows using tool 502377 to push against the nut ensuring the thread starts squarely. Grip the bellows and turn the nut with a 1” A/F spanner until positive resistance is felt. The distance between the nut and the first convolution should be 0 to 1mm.
10. Remove 502382 assembly spigot.
11. Fit mounting brackets (29) to the end plates using 4off M10 Hex Hd screws (17) and washers (12) & (13) tighten to 35Nm. Use loctite 243 on threads.
12. Install vent plugs (31) and elbows (34) to the end plates
|Pump Assembly – Air Motor – Control Valves|
|Pilot Valves (30) - Lightly grease threads and o-rings (grease type #) fit the two pilot valve assemblies into the end plates. Tighten to 0.4Nm (do not over tighten this will damage the valve assembly)
Main Valve (3):
|1. Ensure all parts are free from contamination especially the magnets (43)
2. Lightly grease valve bore of housing (40) and oring of spool assembly (41) Use grease type #
3. Carefully insert the spool assembly into the housing until centrally positioned.
4. Insert bumpers (42) into each end of the spool housing.
5. Insert magnets (43) into end cap (44) then fit oring (48) lubricate with grease type # and assemble into housing
6. Fit seals (47) into housing
7. Position diaphragm (46) into cage (45) and fit into housing (locate cages with relevant pin positions, ensure diaphragm is centrally located)
8. Secure with screws (49)
9. Ensure threaded plugs (50) and (51) are in position
|Assembly Main Valve to Air Motor|
|1. Fit 2 off o-rings (5) and 4off o-rings (6) into air motor end plates (24)
2. Secure main valve assembly (3) onto the end plates with 4 off cap head screws (11)
3. Fit sealing o-rings (7) onto the exhaust cage (45) lightly grease #
4. Fit exhaust adapter (32) using screws (14) and washers (18) & (19) onto the main valve.
|Pump Assembly – Fluid Section - Ball Checks|
|Assemble the Piston|
1. Insert spring (55) and spring keep (68) into the piston
2. Place the ball (61) against spring keep.
3. Fit the ‘O’ ring (72) and inlet seat (70) into the piston (66).
4. Fit piston keep plate (67) and assemble with 5 off M5x25 caphead screws (56) use Loctite 222 on the threads. Tighten evenly to 8Nm.
|Assemble the outlet ball check|
|1. Place ball (62) into outlet check (63)
2. Fit o-ring seal (73) and outlet seat (69) into outlet check.
3. Fit o-ring seal (73) onto outlet cylinder (64)
4. Position the outlet check onto the outlet cylinder.
5. Secure with of 4 off M6 x 20 caphead screws (57) (Grease threads) and washers (59). Tighten evenly to 10Nm.
|Pump Assembly – Fluid Section / Air Motor|
|1. Mount inlet cylinders (65) onto air motor end plates and over each shaft and bellows.
Secure loosely with lightly greased 4off M10x35 cap head screws (60) and 4off Ø10 washers (58). Do not tighten at this stage as this may lead to bellows damage when assembling the piston to the shaft.
2. Apply loctite 243 to the piston shaft threads and screw the piston assemblies onto shafts, tighten up to 50 Nm. Note: If both fluid sections are being assembled tighten by holding one piston with its 14mm hexagon socket and torque the other piston using its socket.
4. Lightly grease with type # the pistons and fit the piston seals (71), wear lip pointing away from the shaft thread.
5. Fit outlet cylinder sub-assembly over the seal, secure with lightly greased 4off M10x35 caphead screws (60) and assemble with 4off Ø10 washers (58) to hold the cylinders together. Tighten evenly all the cap head screws to 40Nm.
6. Tighten the caphead screws holding the inlet cylinder to the air motor to 40Nm
7. Mount inlet (82) and outlet (83) manifold to the fluid sections using clamps (84) and seals (85) to orientation required.
8. Install mufflers (81) into exhaust adapter. Alternatively hose fitting (192802) and 1” plug (192803) can be fitted where piped exhaust is required.
|Pump Assembly – Fluid Section / Air Motor|
|Removal of a Single Fluid Piston|
|The working life and thus the expected life prior to replacement of parts within a Paint Pump are greatly affected by three main factors:
• Abrasiveness of Fluid Pumped
• Pump Duty Cycle
• Fluid Pressure Output requirement
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