Service Manual

EN

Maple 30/3 Pump

• Model 104010

77-3235 R4.5 www.carlisleft.com

Product Description / Object of Declaration: Pumps - Maple, DVP, 104009, 104010/LS, 104016, EN
104027, 104032, 104040/1/2, 104077, 104020,
104023, 104025, 104028/9, 106933, 104205,104149-
52, 104207-15.
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)

Lodging of Technical file
This Declaration of conformity / Carlisle Fluid Technologies UK Ltd,
incorporation is issued under the sole Ringwood Road,
responsibility of the manufacturer: Bournemouth, BH11 9LH. UK

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
EN 1127-1:2011 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 D Smith Director of Sales (EMEA)
Technologies UK Ltd: 13/4/17 Bournemouth,BH11 9LH,UK

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In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as EN
follows:

WARNING CAUTION NOTE

Hazards or unsafe practices which could result in Hazards or unsafe practices which could result in
Important installation, operation or maintenance
severe personal injury, death or substantial property minor personal injury, product or property
information.
damage. damage

WARNING
Read the following warnings before using this equipment.
READ THE MANUAL. Before operating finishing equipment, read and AUTOMATIC EQUIPMENT. Automatic
understand all safety, operation and maintenance information equipment may start suddenly without
provided in the operation manual. warning.

WEAR SAFETY GLASSES. Failure to wear safety glasses with side

PROJECTILE HAZARD. You may be
shields could result in serious eye injury or blindness.
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. KNOW WHERE AND HOW TO SHUT
OFF THE EQUIPMENT IN CASE OF AN
EMERGENCY.

NOISE LEVELS. The A-weighted sound level of pumping and spray

equipment may exceed 85 dB(A) depending on equipment settings. PRESSURE RELIEF PROCEDURE.
Actual noise levels are available on request. It is recommended that Always follow the pressure relief
ear protection is worn at all times while equipment is in use. 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 OPERATOR TRAINING. All personnel
you are uncertain about its condition. must be trained before operating
finishing equipment.

EQUIPMENT MISUSE HAZARD. Equipment misuse can cause the

equipment to rupture, malfunction or start unexpectedly and result
in serious injury. PACEMAKER WARNING. You are in the
presence of magnetic fields which may
interfere with the operation of certain
HIGH PRESSURE CONSIDERATION. High pressure can cause serious pacemakers.
injury. Relieve all pressure before servicing. Spray from the gun,
hose leaks or ruptured components can inject fluid into your body
and cause extremely serious injury.
KEEP EQUIPMENT GUARDS IN PLACE.
Do not operate the equipment if the
safety devices have been removed.
STATIC CHARGE. Fluid may develop a static charge that must be
dissipated through proper grounding of the equipment, objects to be
sprayed and alll other electrically conductive objects in the
NEVER MODIFY THE EQUIPMENT. Do
dispensing area. Improper grounding or sparks can cause a
not modify the equipment unless the
hazardous condition and result in fire, explosion or elecrtic shock and
manufacturer provides written
other serious injury.
approval.

PINCH POINT HAZARD. Moving parts

PROP 65 WARNING. WARNING:This product contains chemicals
can crush and cut. Pinch points are
known to the state of California to cause cancer and birth defects or
any areas where ther are moving
other reproductive harm.
parts.

IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE

OPERATOR OF THE EQUIPMENT.

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 EN

Specification

Ratio: 3:1

Maximum air inlet pressure: 7 bar [101.5 psi]

Maximum fluid pressure: 21 bar [304.5 psi]

Nominal flow volume / cycle: 0.75 l/m [0.20 US gal/m]

Output @ 60 cycles / min: 45 l/m [12 US gal/m]

Maximum recommended continous cycle rate:Cycles/min 20

Maximum recommended intermittent cycle rate:Cycles/min 40

Fluid inlet connection: 1 1/2" Sanitary

Fluid outlet connection: 1 1/2" Sanitary

Compressed Air Inlet 3/8" BSPP / NPSM

Air volume / cycle @ 3.1 bar/45psi: 9.5 l/m [0.33 SCFM] @ 3.1 bar [45 psi]

Air volume / cycle @ 6.2 bar/90psi: 18.5 l/m [0.65 SCFM] @ 90 psi [6.2 bar]

Air consumption @ 15 cycles/min and 6 bar [87 psi] air

283 l/m [10 CFM]
inlet pressure:
Air consumption @ 30 cycles/min and 6 bar [87 psi] air
595 l/m [20CFM]
inlet pressure:

Max. Pump Fluid Inlet Pressure 2 bar [30 psi]

Dirt: 5 microns
Air Quality ISO 8573.1 Class 3.3.2
Water: -20°C @ 7bar [940ppm]
# See Note Oil: 0.1mg/m³

Weight: 35 kg / 77 lbs

# Note: 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.

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Dimensions and Mounting Details

1 ½" Sanitary outlet

1 ½" Sanitary inlet

MOUNTING LOCATIONS 3/8" BSP/NPS

SECTION A-A Air Inlet

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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.

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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.

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.

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 EN

PARTS LIST - Pump Assembly

ITEM PART NO. DESCRIPTION QTY REMARKS

1 160513 SPRING 2 
M8
2 164472 SOCKET HEAD CAP SCREW 8
x 25
3 164838 No.2 x 4.75 RIVET 2
4 165108 M8 SPRING WASHER 8
5 165137 M12 SPRING WASHER 16
M12
6 165960 SOCKET HEAD CAP SCREW 16
x 40
Ø1
7 171788 BALL 2 
3/8"
8 192008 1 1/2" SANITARY GASKET 4 #
1&
9 192009 SANITARY CLAMP 4 #
1 1/2"
10 192505 Ø12.42 x 1.78 O-RING 4
11 192551 1/4" BSP HEXAGON PLUG 4
12 192595 OUTLET CHECK 2
13 192596 OUTLET CYLINDER 2
14 192597 INLET CYLINDER 2
15 192626 BALL CAGE 2
16 192629 INLET SPRING KEEP 2 
17 192632 SEAT 2 
18 194237 PISTON SEAL 2 #
19 192647 Ø50.52 x 2.62 O-RING 2 
20 192648 Ø41.0 x 1.78 O-RING 2 
21 192775 INLET MANIFOLD 1
22 192776 OUTLET MANIFOLD 1
23 192777 1" VALVE MUFFLER 2

23 192821 1" HEAVY DUTY MUFFLERS 2 104010-LS

24 192816 BINKS NAMEPLATE 1

25 193705 AIR MOTOR ASSEMBLY 1
26 193775 LABEL 1
27 194243 Ø100 PISTON ASSEMBLY 2

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Pump Assembly

KEY

GREASE
(AGMD-010)

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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 EN

PARTS LIST - Air Motor Assembly

ITEM PART NO. DESCRIPTION QTY REMARKS

1 0115-010037 POPPET ASSEMBLY 2 #

2 0115-010102 AIR VALVE ASSEMBLY 1 #
3 161992 Ø117.5 x 2.62 O-RING 2 
4 161993 Ø20.35 x1.78 O-RING 2 
5 161994 Ø4.47 x 1.78 O-RING 4 
6 161995 Ø19.5 x 3.00 O-RING 2 
7 162703 SHAFT SEAL 2 
8 162704 SHAFT BEARING 2 
M6
9 163920 SOCKET HEAD CAP SCREW 4
x 30
10 165108 M8 SPRING WASHER 16
M4
11 165528 SOCKET HEAD CAP SCREW 4
x 16
12 165963 M8 DOME NUT 16
13 165970 M4 PLAIN WASHER 4
14 165971 M4 SPRING WASHER 4
M10
15 177038 BUTTON HEAD CAP SCREW 4
x 12
16 192374 RETAINING NUT 2
17 192579 KNIFED BELLOWS 2 #
18 192757 AIR CYLINDER 1
19 192761 CYLINDER STUD 6
20 192762 CYLINDER STUD - LONG 2
21 192763 BELLOWS SPACER 2
22 192764 PUMP BRACKET 2
23 192799 VENT PLUG 2
24 192812 EXHAUST ADAPTER 1

25 192814 BELLOWS LEAK DETECTION HOSE 1 

1/8R
26 192815 PUSH IN ELBOW 2
- 6mm
27 194293 AIR MOTOR PISTON ASSY 1

28 194599 END PLATE MACHINING 2

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 KEY
ITEM 7
GREASE
DETAIL
(AGMD-010)

77-3235 R4.5
LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

11/24
EN

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 EN

194293 - Air Motor Piston Assembly

ITEM PART NO. DESCRIPTION QTY REMARKS

1 162702 AIR MOTOR PISTON SEAL 1 

2 165964 M12 x 40 GRUB SCREW 1

3 192759 PISTON SHAFT 2

4 192760 PISTON 1

KEY
GREASE
(AGMD-010)

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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Air Valve Assembly

ITEM PART NO. DESCRIPTION QTY REMARKS

1 0115-010015 SPOOL AND SLEEVE ASSEMBLY 1 #

162789 SPOOL AND SLEEVE O-RING 6 Not Shown

2 0115-010016 BUMPER 2 
3 0115-010017 MAGNET 2 
4 0115-010018 VALVE BLOCK END CAP 2
5 0115-010020 DIAPHRAGM 2 
6 0115-010021 1.5 x 36 O-RING 2 
7 0115-010049 2 x 20 O-RING 2 
8 0115-010073 M4 x 12 BUTTON HEAD CAP SCREW 8

9 0115-010097 VALVE BLOCK 1

10 0115-010103 1/4 BSPT PIPE PLUG 1
11 0115-010107 1/8 BSPT PIPE PLUG 1
12 180584 3/8" UNIVERSAL FITTING 1

13 192813 QUICK EXHAUST VALVE CAGE 2

KEY
GREASE
(AGMD-010)

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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194243 - Fluid Piston Assembly

ITEM PART NO. DESCRIPTION QTY REMARKS

1 160513 PISTON BALL CHECK SPRING 1 

2 162805 Ø63.17 x 2.62 O-RING 1 
3 162807 Ø50.52 x1.78 O-RING 1 
4 162854 Ø82.22 x2.62 O-RING 1 
5 171784 1.375 BALL 1 
6 192629 INLET SPRING KEEP 1 
7 192631 SEAT 1 
8 193626 Ø100 FLUID PISTON 1
9 193627 BALL CAGE 1

Use a 32mm Single Hex

Socket when tightening or
removing ball cage
from Piston.

KEY
GREASE
(AGMD-010)

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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 EN

Fault Finding

Symptom Possible Cause Remedy

Check seals and hose

Air getting into the suction hose/manifold
connections.

Pump will not

Worn piston seal. Replace piston seals.
‘Prime’

Inspect, clean and/or replace

Ball checks not seating correctly.
balls and seats.

Check air and fluid supply ball

No air or fluid supply
valves and supply hoses.

Air piston seal worn. Replace piston seal.

Switch/interchange pilot valves

Pilot valve assemblies inoperable. to isolate faulty pilot valve and
clean/replace.

Pump will not run

Main air valve inoperable. Check clean/replace Air valve.

Check for constant exhaust air when

pump is not running.
QE diaphragm defective.

Check/replace QE diaphragms.

Inspect, clean and/or replace

Ball checks not seating correctly.
balls and seats.

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 EN

Fault Finding

Symptom Possible Cause Remedy

Check seals and hose

connections.
Air getting into fluid line, air supply restricted.

Check air supply

Remove, clean, and inspect seat,

ball, and ball cage.
Obstructed fluid ball checks.

Replace if suspect or worn.

Pump runs but has

excessive pulsation. Worn air motor piston seals. Replace air motor piston seal.

Disassemble pump as required

Worn/failed air motor shaft seals.
to replace air motor shaft seals.

Worn fluid piston seal. Replace fluid piston seal.

Check QE diaphragms and

Air exhaust restricted.
exhaust outlets.

Bellows seal failure Replace bellows seal

Paint leaking into
detection hose, air
bleeding from vent
plug Check air motor shaft seal
Air motor shaft seal leaking
replace as necessary

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 EN

Spares Kits for Maple 30 Pump

KIT No. PART NO. DESCRIPTION QTY REMARKS

 250768** Fluid section seal kit 1

Check main parts list

 250738** Fluid overhaul kit 1
for details of
individual kit contents
 250618 Air Motor Seal Kit 1

 250628* Control Valve Kit 1

# 0115-010037* Poppet Assembly 1 2 off per pump

# 0115-010015 Main Spool & Sleeve Valve Assembly 1 1 off per pump

# 194237 Piston seal 1 2 off per pump

# 192579 Knifed Bellows 1 2 off per pump

# - Recommended spare parts for continually running pumps

* Pumps before serial number 53971 will require; Pilot spool assembly 192765, Control valve kit 250620.

** Note:
Fluid section seal & fluid section overhaul kits contain all the necessary components to service Mark one
and two pistons.

Discard components not required.

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 EN

Maintenance schedule

Inspection Operation

Daily Check for any general fluid or air leakage.

Inspect Pump for Correct operation

Weekly 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
6 Month Test 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.
12 to 36 Months (Typically
10 million pump cycles Inspect and replace if required:
dependant on air quality and Pilot Air Valves & Main Air Valve Parts.
abrasiveness of the paint
used)
Replace fluid piston seal,
Replace Balls,Seats and Bellows.

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 EN

Bellows Replacement

ITEM PART NO. DESCRIPTION QTY REMARKS

1 502769 Bellows positioning tool 1

2 502382 Bellows assembly spigot 1

2 1

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.

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 EN

Accessories

ITEM PART NO. QTY

192008 1 & 1 1/2" Sanitary Gasket

192009 1 & 1 1/2" Sanitary Clamp

502608 Seal Insertion Tool For Shaft seal (7)

502769 Bellows Positioning Tool

502382 Bellows assembly spigot

AGMD-010 Kluber Isoflex Topas NB 52 Grease 50ml Tube

192779 Exhaust Tube Adapter (1” NB hose) For piped exhaust

192820 Exhaust Tube Adapter (1” NB hose) For piped exhaust

192803 1" Manifold Plug For piped exhaust

Recommended for high pump

192821 1" BSP Heavy Duty Mufflers
pressures and cycle rates

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NOTES

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NOTES

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NOTES

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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.

© 2018 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 Brazil

www.binks.com www.carlisleft.com.mx www.devilbiss.com.br
[email protected] [email protected] [email protected]
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Tel: 011 52 55 5321 2300 Tel: +55 11 5641 2776
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www.carlisleft.eu www.carlisleft.eu www.carlisleft.eu
[email protected] [email protected] [email protected]
Tel: +44 (0)1202 571 111 Tel: +33(0)475 75 27 00 Tel: +49 (0) 6074 403 1
Fax: +44 (0)1202 573 488 Fax: +33(0)475 75 27 59 Fax: +49 (0) 6074 403 281

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[email protected] [email protected] [email protected]
Tel: +8621-3373 0108 Tel: 081 45 785 6421 Tel: +61 (0) 2 8525 7555
Fax: +8621-3373 0308 Fax: 081 45 785 6517 Fax: +61 (0) 2 8525 7575

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