Service Manual

EN

E2-30/40 Electric Drive

Pump
E2-30 E2-40
• 107071 (EU Model) • 107093 (EU Model)
• 107074 (USA Model) • 107094 (USA Model)
• 107075 (Japan Model) • 107095 (Japan Model)

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 Carlisle Fluid Technologies representative for additional copies of this manual.

READ ALL INSTRUCTIONS BEFORE OPERATING THIS PRODUCT

77-3215 R5.5 1/40 www.carlisleft.com

Product Description / Object of Declaration: Electric Pump E2, E4, EV2 EN

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 (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 (0891)

Lodging of Technical file

This Declaration of conformity / incorporation Carlisle Fluid Technologies UK Ltd,

is issued under the sole responsibility of the Ringwood Road,
manufacturer: Bournemouth, BH11 9LH. UK

EU Declaration of Conformity 
This Declaration of conformity / incorporation is issued under the sole responsibility of the
manufacturer:
Machinery Directive 2006/42/EC
ATEX Directive 2014/34/EU
EMC Directive 2014/30/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"
EN 13463-8:2003 Non-electrical equipment for potentially explosive atmospheres. Protection by liquid immersion
'k'
EN 60079-0:+A11:2013 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.

D Smith Director of Sales (EMEA)

Signed for and on behalf of Carlisle Fluid
Technologies UK Ltd:
29/6/18 Bournemouth,BH11 9LH,UK

77-3215 R5.5 2/40 www.carlisleft.com

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 you OPERATOR TRAINING. All personnel
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 dispensing NEVER MODIFY THE EQUIPMENT. Do
area. Improper grounding or sparks can cause a hazardous condition not modify the equipment unless the
and result in fire, explosion or electric shock and other serious injury. manufacturer provides written
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
Nominal pump stroke: 50mm [1.97 ins]

E2-30* Maximum fluid pressure: 20.7 bar [300psi]

E2-40* Maximum fluid pressure: 16 bar [232psi]

E2-30 Nominal flow volume / cycle: 0.75 l/m [0.20 US gal/m]

E2-40 Nominal flow volume / cycle: 1.00 l/m [0.26 US gal/m]

E2-30 Fluid Output @ 20 HZ [10 cycles/min] 7.5 l/m [2.0 US gal/m]

E2-40 Fluid Output @ 20 HZ [10 cycles/min] 10 l/m [2.64 US gal/m]

E2-30 Fluid Output @ 80 HZ [40 cycles/min] 30 l/m [8.0 US gal/m]

E2-40 Fluid Output @ 80 HZ [40 cycles/min] 40 l/m [10.6 US gal/m]

Fluid inlet connection: 'A'

1 ½'' Sanitary
Fluid outlet connection: 'B'
Gearbox Ratio: 56:1

Gearbox Oil (EU Model) Synthetic 220 (typically Agip Blasia S)

Gearbox Oil (USA Model) SHC 630 Synthetic Oil

AC Induction Electric Motor- EU Model 400V 3PH 1.5 kW @ 50HZ

0.75 kW 4Pole 1400 RPM EEx d 11B T3

0.75 kW 4Pole 1400 RPM - Japan Model Rated 20 to 80 Hz (c/w thermisters)

460V 3PH 1 Hp @ 60HZ

Class 1, Group D.
AC Induction Electric Motor - USA Model
Rated 20 to 80 Hz (c/w thermisters)

Total Weight of Pump (inc electric motor) 250 kg [550 lbs]

Max. Inlet Pressure 2 bar [29 psi]

NOTE
* Pressure when used in 'Smart Mode' (Closed Loop Pressure Mode)

Reduce Maximum working pressure by 2 bar [29 psi] when using in Open Loop Flow Mode

e.g. E2-15 Maximum Set Pressure of 18 bar to operate Pump on a 24/7 basis

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 EN

DIMENSIONS AND MOUNTING DETAILS

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.

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 EN

INSTALLATION

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.

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.

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] and 17 bar [246 psi]
respectively.

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.

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 EN

INSTALLATION
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.

Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into
consideration.
Only trained personnel familiar with these standards should handle this type of apparatus.

The motor is fitted with PTC temperature sensors (Thermistors).

Once operating temperature is reached, this device quickly changes the resistance;

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.

Inverter

Required Inverter Settings Value

Maximum Hz Output 80 Hz

Mininmum Hz Output 20 Hz

Acceleration Ramp 5 Seconds

Deceleration Ramp 0.1 Seconds

Rated Motor Power 1.5 kW

Rated Motor Current 3.8 A

Rated Motor Power Factor 0.81

Rated Motor Efficiency 78 %

Rated Motor Frequency 50 Hz

Rated Motor Voltage 400 V

Rated Motor Speed 1440 RPM

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 EN

INSTALLATION

 Attach suitable flexible hoses to the inlet and outlet connections.

e.g.,
 Suction - Ø50 I.D. [-1 to 10 bar working pressure]

 Outlet - Ø38 - 50 I.D. [20 bar working pressure]

 Ensure adequate air space around the Pump for maintenance and electric motor cooling requirements.

 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.

 Ensure the gearbox is filled with oil.

(The gearbox is filled with the correct amount of oil at the factory)

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 EN

SYSTEM OPERATION

Before starting:-
 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.

 Check the gearbox oil level, please note the the gearbox is supplied with life lubricant and does not need
any maintenance.

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.

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 EN

PARTS LIST - Pump Assembly

ITEM PART NUMBER DESCRIPTION QTY REMARKS

1 193709 E2-30/40 MECHANICAL ASSY 1

192669 H063 ATEX GEARBOX 1 EU MODEL

H063 GEARBOX
2 192670 1 USA MODEL
(Not Shown)
H063 GEARBOX
192756 1 JAPAN MODEL
(Not Shown)

192666 1.5KW ATEX MOTOR 1 EU MODEL

3
1.5KW ELECTRIC MOTOR
192667 1 USA MODEL
(Not Shown)
4 163126 M12 HEXAGON NUT 4
5 164470 M12 WASHER 4

6 165044 M12 SPRING WASHER (ST ST) 8

7 165960 M12 x 40 CAP HEAD SCREW 8

194249 E2-30 FLUID SECTION 2

8
192755 E2-40 FLUID SECTION 2

9 194559 COVER C/W CAP FIXINGS 2

194901 E2-30 MANIFOLD & PRV ASSEMBLY 1

10

194902 E2-40 MANIFOLD & PRV ASSEMBLY 1

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 EN
KEY

GREASE

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)
GREASE INTERNAL

(AGMD-010)

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 EN

PARTS LIST - PRV and Manifold Assembly

ITEM PART NUMBER DESCRIPTION QTY REMARKS

104168 E2-30 1.5'' PRESSURE RELIEF VALVE 1 22 bar

1
104201 E2-40 1.5'' PRESSURE RELIEF VALVE 1 16 bar

2 192008 1.5'' SANITARY GASKET - PTFE 10

3 192009 1 & 1 1/2 SANITARY CLAMP 10

4 1
193746 1.5'' SANITARY ELBOW

5 194275 INLET MANIFOLD 1

6 194276 OUTLET MANIFOLD 1
E2-30 1.5'' [119mm] EXT. SANITARY
194591 1
ELBOW
7
E2-40 1.5'' [119mm] EXT. SANITARY
194591 1
ELBOW
E2-30 1.5'' [119mm] EXT. SANITARY
194591 1
ELBOW
8
E2-40 1.5'' [119mm] EXT. SANITARY
194594 1
ELBOW
E2-30 1.5'' [119mm] EXT. SANITARY
194591 1
ELBOW
9
E2-40 1.5'' [119mm] EXT. SANITARY
194594 1
ELBOW

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 EN

KEY

GREASE

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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 EN

PARTS LIST - Mechanical Assembly

ITEM PART NUMBER DESCRIPTION QTY REMARKS

1 163126 M12 HEXAGON NUT 4

2 163161 M8 NYLOC NUT 4

3 164470 M12 WASHER (ST ST) 4

4 165100 M16 SPRING WASHER 10

5 165108 M8 SPRING WASHER 4
6 165123 Ø10 SPRING WASHER 6

7 165371 M16 x 60 HEX HEAD BOLT (PLATED) 4

8 165552 M8 x 20 CAP HEAD SCREW 8

9 165588 M16 x 30 CAP HEAD SCREW 4

165663
10 M8 x 30 GRUB SCREW 4

11 165686 M12 x 50 GRUB SCREW 4

12 165988 M10 x 30 CAP HEAD SCREW 6

13 177020 MUD GUARD WASHER - STST 4

14 177021 M8 x 20 BUTTON HEAD CAP SCREW 4

15 192400 SPRING RETAINING WASHER 4

16 192441 M16 EYE BOLT 2

17 192589 COUPLING ASSY 1
18 192634 MOUNTING FRAME 2
19 192643 LINEAR BEARING ROD 2

20 192650 GREASE NIPPLE 2


21 192662 GREASE HOSE 2

22 192668 SHAFT CLAMP ASSY 2

23 192671 12 x 8 x 40 KEY 1
24 192682 CARRIAGE ASSEMBLY 2

25 192753 LEAK DETECTION HOSE ASSY 1

26 193102 CARRIAGE SPRING ROD 2

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 EN

PARTS LIST - Mechanical Assembly

ITEM PART NUMBER DESCRIPTION QTY REMARKS

27 193104 CARRIAGE SPRING 4

28 193105 SPRING KEEP ASSEMBLY 4

29 193130 1/8''- 6 mm EXTENDED ELBOW 2

30 193131 Ø10 x 1/4'' BSPT EXT ELBOW 2

31 193696 Ø40 SHAFT COUPLING SPACER 1

32 194538 MAIN BODY MACHINING 1

33 194540 SPACER 4

34 194584 BELL HOUSING CAM ASSY 1

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 EN

KEY

GREASE

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

** Tighten bolts holding carriage ends once pump is fully assembled.

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 EN

KEY

GREASE

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
NOTE:
(AGMD-010)
Part No. 1 Grease using 502375
Part No. 4 To be tightened using tool 193120
Part No. 6 To be tightened using tool 193119
Part No. 11 To be pressed into housing using tool 193121
Part No. 12 Remove inner race & grease 502375

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 EN
PARTS LIST - Bell Housing & Shaft Assemblies

ITEM PART NUMBER DESCRIPTION QTY REMARKS

1 163951 M6 x 16 CAP HEAD SCREW 6

2 163952 M6 x 20 CAP HEAD SCREW 6

3 165087 M6 SPRING WASHER 12

4 192616 BEARING CAP 1
5 192617 BEARING CLAMP 1

6 192639 Ø50 x Ø110 x 44.4 SHAFT BEARING 1 

7 195636 Ø45 x Ø100 x 36 SHAFT BEARING 1 

8 192644 Ø58 X Ø80 X 8 SEAL 1 

9 192650 GREASE NIPPLE 1

10 192655 M45 BEARING LOCKNUT 1

11 192656 M50 BEARING LOCKNUT 1

12 193437 BOTTOM BEARING HOUSING 1

13 194512 SHAFT ASSEMBLY 1

14 194539 BELL HOUSING MACHINING 1

15 192600 CONSTANT VELOCITY CAM 1

16 192594 TOP SHAFT 1

17 192606 BASE SHAFT 1

18 165571 M10 x 70 CAP HEAD SCREW 10

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 EN

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 EN

PARTS LIST - Carriage Assembly

ITEM PART NUMBER DESCRIPTION QTY REMARKS

1 192608 LH CARRIAGE END 1

2 192607 CARRIAGE MIDDLE 1
3 192609 RH CARRIAGE END 1
4 192618 CARRIAGE ADAPTOR 1

5 192611 FOLLOWER GUARD WASHER 2

6 192610 CAM FOLLOWER PIN 1

7 192612 FOLLOWER NUT WASHER 1

8 192641 Ø72 CAM FOLLOWER 1 

9 192642 LINEAR BEARING 4 

10 192615 LINEAR BEARING SPACER 2

11 192652 Ø47INTERNAL CIRCLIP 4 

12 165108 M8 LOCKWASHER 6

13 165553 M8 x 25 CAP HEAD SCREW 6

14 165552 M8 x 20 CAP HEAD SCREW 2

15 163152 M16 NYLOC NUT 1

16 192649 1/8'' GREASE NIPPLE - SLIP ON 2

17 192661 1/8R - 6mm PUSH IN ELBOW 1

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 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

GREASE

LOCTITE
Tighten on final assembly to give
TORQUE correct orientation for hose
connection to grease nipple.
MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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 EN

PARTS LIST - E2-30 Fluid Section

ITEM PART NUMBER DESCRIPTION QTY REMARKS

1 160513 BALL CHECK SPRING 1 

2 163921 M6 x 25 CAP HEAD SCREW 4

3 164472 M8 x 25 CAP HEAD SCREW 4

4 165044 M12 SPRING WASHER 8

5 165087 M6 SPRING WASHER 4
6 165108 M8 SPRING WASHER 4

7 165960 M12 x 40 CAP HEAD SCREW 8

8 171788 Ø1 3/8'' ST ST BALL 1 

9 192505 12.42 x 1.78 O-RING 2 

10 192551 1/4 BSP HEXAGON PLUG 2

11 192595 OUTLET CHECK 1

12 192596 OUTLET CYLINDER 1
13 192597 INLET CYLINDER 1
14 192626 OUTLET CAGE 1

15 192629 INLET SPRING KEEP 1 

16 192632 SEAT 1 
17 194237 PISTON SEAL 1 

18 192647 50.5 x 2.62 O-RING 1 

19 192648 41.0 x 1.78 O-RING 1 

20 192679 SHAFT/BELLOWS ASSY 1

21 194243 PISTON ASSEMBLY 1

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 EN
KEY

GREASE

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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 EN

PARTS LIST - E2-40 Fluid Section

ITEM PART NUMBER DESCRIPTION QTY REMARKS

1 160513 BALL CHECK SPRING 1 

2 163921 M6 x 25 CAP HEAD SCREW 4

3 164472 M8 x 25 CAP HEAD SCREW 4

4 165044 M12 x 40 SPRING WASHER 8

5 165108 M8 SPRING WASHER 4

6 165960 M12 x 40 CAP HEAD SCREW 8

7 165087 M6 x 25 SPRING WASHER 4

8 171788 Ø 1 3/8'' ST ST BALL 1 

9 192505 12.42 x 1.78 O-RING 2 

10 192551 1/4 BSP HEXAGON PLUG 2

11 192595 OUTLET CHECK 1

12 192626 OUTLET CAGE 1

13 192629 INLET SPRING KEEP 1 

14 192632 SEAT 1 

15 192647 50.5 x 2.62 O-RING 1 

16 192648 41 x 1.78 O-RING - PTFE 1 

17 192679 SHAFT/BELLOWS ASSY 1

18 194244 PISTON ASSEMBLY 1

19 192789 OUTLET CYLINDER 1
20 192790 INLET CYLINDER 1
21 194238 PISTON SEAL 1 

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 EN

KEY

GREASE

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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 EN

PARTS LIST - E2-30 Piston Assembly

ITEM PART NUMBER DESCRIPTION QTY REMARKS

1 160513 BALL CHECK SPRING 1 

2 162805 63.17 x 2.62 O-RING 1 

3 162807 50.52 x 1.78 O-RING 1 

4 162854 82.22 x 2.62 O-RING 1 

5 171784 1.75 ST ST BALL 1 

6 192629 INLET SPRING KEEP 1 

7 192631 PISTON INLET SEAT 1 

8 193626 FLUID PISTON 1

9 193627 BALL CAGE 1

Use a 32mm Single Hex Socket

when tightening or removing ball
cage from Piston.

KEY

GREASE

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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 EN

PARTS LIST - E2-40 Piston Assembly

ITEM PART NUMBER DESCRIPTION QTY REMARKS

1 160513 BALL CHECK SPRING 1 

2 162805 63.17 x 2.62 O-RING 1 

3 162807 50.52 x 1.78 O-RING 1 

4 162854 82.22 x 2.62 O-RING 1 

5 171784 1.75 ST ST BALL 1 

6 192629 INLET SPRING KEEP 1 

7 192631 PISTON INLET SEAT 1 

8 193627 BALL CAGE 1

9 194112 FLUID PISTON 1

Use a 32mm Single Hex

Socket when tightening or
removing ball cage
from Piston.

KEY

GREASE

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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 EN

PARTS LIST - Shaft & Bellows Assembly

ITEM PART NUMBER DESCRIPTION QTY REMARKS

1 192374 RETAINING NUT 1

2 192579 KNIFED BELLOWS 1 
3 192627 BELLOWS SPACER 1
4 192628 SHAFT SEAL 1 
5 192619 PISTON SHAFT 1

6 502377 BELLOWS POSITIONING TOOL 1 TOOL

7 502382 BELLOWS ASSEMBLY SPIGOT 1 TOOL

Screw Item No. 2 (assembly

spigot) onto the piston shaft
(grease spigot with AMGD-010).

Using Item No. 7, 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.

KEY

GREASE

LOCTITE

TORQUE

MAINTENANCE ORDER
(Reverse for assembly)

GREASE INTERNAL
(AGMD-010)

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 EN

Maintenance

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: -

• Abrasiveness of Fluid Pumped

• Pump Duty Cycle
• Fluid Pressure Output Requirement

The two components which are more greatly affected by the above criteria than any other components in the
pump are:

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.

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 EN

Maintenance

Maintenance schedule

Inspection Operation

Daily Check for any fluid leakage

Check for any excessive mechanical noise

Check for excessive fluid pressure pulsation

Weekly

Check oil level within gearbox

While running, apply (502375) grease to cam follower bearings, 8 strokes of a

3 Monthly
standard ‘cartridge’ grease gun (502373).

Grease Main Shaft Bearing with 502375 grease.

6 Monthly Inspect Linear Bearings, Rod, Cam and Cam followers for excessive wear, replace
if excessive wear can be felt or seen.

Inspect Piston and Replace Piston Seals / Bellows / Springs.

Inspect Piston & Outlet Ball Checks, replace as necessary.

Annually
Inspect Linear Guide Bearing and Guide Rails for excessive wear.

Inspect Cam and Cam followers for excessive wear, replace if excessive wear can
be seen.

Replace main shaft bearings. Linear Guide Bearings, Guide Rails and Cams if
Every 5 Years excessive wear can be seen.

Drain and replace gearbox oil

Use only 502375 (KP2N-20 DIN 51825) Grease for Cam Follower Bearing.

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 EN

Maintenance

Gearbox

WARNING
Wait until the unit has cooled sufficiently after stopping and isolation.

Gearbox
Every 1000 hours verify the good condition of oil seals and gaskets

Maintenance
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.

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.

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Maintenance

Motor

WARNING
Wait until the unit has cooled sufficiently after stopping and isolation.

Electric Motors
Maintenance of Ex Motors - are reported by EN 60079-17 standard, in particular:-

• The electric connections must be correctly locked to avoid resistance-increases, with consequent contact
overheating.

• 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.

• 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 join surfaces have just to be cleaned and, in order to avoid corrosion or water entrance.

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:

• Sufficient technical knowledge of these 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.

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Fault Finding

Mechanics

Symptom Possible Cause Remedy

Gearbox Output shaft does not

Drive between shafts in the gear unit Return the unit for repair and replace
rotate, even though the motor is
interrupted gearbox
running.

Gearbox Oil leaking

a) Defective gasket on gear unit a) Retighten screws on gear
• from the gear unit cover cover. unit cover.

• from the motor flange b) Defective gasket. b) Return gearbox

• from the gear unit flange
c) Gear unit not ventilated c) Check vent is clean/fitted and
• from the output oil seal not the transportation plug

Gearbox Oil leaking from ventilator Unit overfilled with oil. Check and correct the oil level

Cam Followers bearing generating Grease bearing or replace if damage

Bearing needs lubrication
heat / noise is too great

a) Spring tension insufficient Check and replace springs

Carriage does not maintain contact b) Fluid seal friction or piston Check fluid section
with cam movement prevented

a) Spring tension insufficient

b) Fluid seal friction or piston

Noisy Changeover movement prevented Replace green spider coupling

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Fault Finding

Fluid Section

Symptom Possible Cause Remedy

a) Air entering the suction a) Check o-rings and hose

hose/manifold connections

Pump will not ‘Prime’ b) Worn piston seals b) Replace piston seals.

c) Ball checks not seating c) Inspect, clean and/or replace

correctly. balls and seats.

a) No power a) Check electrical supply

b) Inverter Unit or safety b) Check inverter and fault

Pump will not run interlocks ‘tripped’ conditions

a) Worn piston seals a) Replace piston seals.

b) Inverter Unit or safety b) Inspect, clean and/or replace

Pump runs, but lack of pressure interlocks ‘tripped’ balls and seats.

Replace bellows seal, check piston

Paint leaking from inside cover Bellows seal failure
seal, replace as necessary

a) Ball checks not seating

correctly.

b) Main shaft bearings worn

Replace bellows seal, check piston
Excessive Pressure Pulsation
c) Cam follower worn seal, replace as necessary

d) Cam direction incorrect

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Testing and Lubricating

Testing and Lubricating after major overhaul
WARNING
Testing and Lubricating - Qualified personnel only

1 Connect pump to paint system.

2 Connect electric motor to a suitable electrical supply.
3 Fit the gearbox vent plug.
4 Turn on paint system and set back pressure regulator to zero.
5 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

6 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.
7 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).

9 Run the pump at 20 cycles/min [50 HZ] and increase the back pressure to 10 bar and run for 1 hour.

Check for any leaks and mechanical noises.

Fluid Drain Down

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.

3 Start the pump and run at slow speed [20Hz] for 1 minute.

The pump will now have most of the paint removed;

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.

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Spare Parts List

Recommended Replacement Spare Parts and Kits

for E2-30/40 Pumps

KIT No. Part No. Description Remarks

# 192600 Constant Velocity Cam

# 193626 Ø100 Piston E2-30

# 194112 Ø114 Piston E2-40

 250768** Fluid section seal kit E2-30

 250796** Fluid section seal kit E2-40

 250738** Fluid Section overhaul kit E2-30

 250786** Fluid Section overhaul kit E2-40

 250609 Bellows replacement kit

 250611 Cam Follower Bearing Kit

 250612 Linear Guide and Rod Kit

 250599 Main Bearing Overhaul Kit

# 502672* * Cam Upgrade Kit

#
192688 Auto Lubrication Kit Cam Follower Bearing
#

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.

** Please note,
fluid section seal kits contain all the necessary components to service mark one and mark two fluid
pistons.

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ACCESSORIES

PART NUMBER DESCRIPTION REMARKS

192800 Smart Card

502501 BPR Control Box

502483 Electrical Panel for Single Pump Operation Inc. Smart Card

Grease Gun for Cam Follower

502373 Collet Connector
(& Main Bearings)

Grease Gun for Linear Bearings

502514 Hook Connector
(300mm Extension)
Grease for Cam Follower
502375
(& Main Bearings)
502376 Grease for Linear Bearings
192720 Sensor Manifold
Pressure Sensor
192547 Pressure Feedback
[4-20 mA / 0-25 bar]
192008 1.5'' Sanitary Gasket
192009 1.5'' Sanitary Clamp
194237 E2-30 Fluid Piston Seal
194238 E2-40 Fluid Piston Seal

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ACCESSORIES

PART NUMBER DESCRIPTION REMARKS

192450 M8 Torx Security Screwdriver for Cover FOC with a New Pump
502508 Top Bearing Locknut Tool
502509 Bottom Bearing Locknut Tool
502510 Top Bearing Press Tool
502511 Bottom Bearing Press Tool
502512 Shaft Assembly Tool
502377 Bellows Assembly Tool
502382 Bellows Assembly Spigot

502508 502509 502510

502511 502512 502377 & 502382

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NOTES

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WARRANTY POLICY

This product is covered by Carlisle Fluid Technologies’ materials and workmanship limited
warranty. The use of any parts or accessories, from a source other than Carlisle Fluid
Technologies, will void all warranties. Failure to reasonably follow any maintenance guidance
provided, may invalidate any warranty.

For specific warranty information please contact Carlisle Fluid Technologies.

Carlisle Fluid Technologies is a global leader in innovative finishing technologies.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.
© 2020 Carlisle Fluid Technologies,Inc.
All rights reserved.

For technical assistance or to locate an authorised distributor, contact one of our international sales and customer
support locations below.

Region Industrial / Automotive Automotive Refinishing

Tel: 1-888-992-4657 Tel: 1-800-445-3988

Americas
Fax: 1-888-246-5732 Fax: 1-800-445-6643

Europe, Africa,
Tel: +44 (0)1202 571 111
Middle East,
Fax: +44 (0)1202 573 488
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Tel: +8621-3373 0108

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Fax: +8621-3373 0308

Tel: +81 45 785 6421

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Fax: +81 45 785 6517

Tel: +61 (0) 2 8525 7555

Australia
Fax: +61 (0) 2 8525 7575

For the latest information about our products, visit www.carlisleft.com

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