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E420 Gun Manual 77-3345
- E420 Gun Manual 77-3345 [ English ]
EN
OPERATING MANUAL
www.binks.com
Binks E420
Swiveling applicator for Robotic
Sealing Applications
EN
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1. Safety information ................................................................... 3
1.1 Warnings ............................................................................. 4
2. Description ................................................................................ 5
2.1 Central body ........................................................................ 6
2.2 Swivel housing ...................................................................... 8
2.3 Connection housing ............................................................ 11
2.4 Nozzle head ....................................................................... 12
2.5 Cylinder assembly ............................................................... 13
2.6 Swivel locking bracket .......................................................... 14
2.7 Mounting flange ................................................................. 15
2.8 Tools ................................................................................. 16
3. Installation instructions ........................................................ 17
4. Dismounting instructions ....................................................... 22
5. Disassembly instructions ....................................................... 24
6. Assembly instructions ............................................................ 40
6.1 Testing before installation .................................................... 56
7. Technical specifications ......................................................... 57
8. Dimensions ............................................................................. 58
9. Maintenance .......................................................................... 60
This manual contains important information about warnings and cautions. Read the manual thoroughly
before starting to operate this equipment, and carefully follow the instructions. Always keep the manual
handy until such time the equipment is no longer being used. If your manual is lost or damaged,
immediately contact your supplier for a new copy.
Content:
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1. Safety Information
Thank you very much for choosing the Binks E420 sealing applicator.
In order to keep the equipment in the best condition for an extended period, please carefully
read this manual before use. Above all, the specifications, warnings, and prohibitory or
cautionary instructions shown shall be fully understood and observed while using the
equipment.
The equipment covered by this manual is designed for automotive sealing applications. It shall
only be used by those who have been correctly trained regarding the handling and scope of
application and have a full understanding of the operating procedure.
If you need further information about this product, please contact your supplier and refer to
the model and serial No. of your equipment.
The Binks E420 is designed for safe operation. It’s important that the conditions for safe
operation are respected so that accidents and personal injury are prevented.
These safe conditions are described in this manual.
Only qualified maintenance personnel may perform maintenance work on this equipment.
All personnel handling this equipment must study this manual so that they are familiar with
the equipment, how it operates, and all safety measures.
Keep the equipment clean at all times to ensure safe operation.
Make sure to release pressure from the material supply system before attempting any
maintenance work on the Binks E420 applicator.
To prevent any personal injury or equipment damage, make sure that the maximum operating
pressures are not exceeded.
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In this manual, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as follows:
Read the following warnings before using this equipment
! WARNING
NOTE
or
in
or
in minor
AUTOMATIC EQUIPMENT
Automatic equipment may start suddenly without warning.
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.
NEVER MODIFY THE EQUIPMENT
Do not modify the equipment unless the manufacturer provides written
approval.
NOISE HAZARD
You may be injured by loud noise. Hearing protection may be required when
using this equipment.
READ THE MANUAL
read and all safety,
and maintenance in the
TRAINING
All must be before equipment.
EQUIPMENT HAZARD
can cause the to or start
and result in injury.
LOCK OUT / TAG-OUT
Failure to de-energize, disconnect, lock out and tag-out all power sources
before performing equipment maintenance could cause serious injury or
death.
PRESSURE RELIEF PROCEDURE
Always follow the pressure relief procedure in the equipment instruction
manual.
KEEP EQUIPMENT GUARDS IN PLACE
Do not operate the equipment if the safety devices have been removed.
KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT IN CASE
OF AN EMERGENCY
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.
STATIC CHARGE
Fluid may develop a static charge that must be dissipated through proper
grounding of the equipment, objects to be sprayed and all 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.
PROP 65 WARNING
WARNING: This product contains chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm.
WEAR RESPIRATOR
Toxic fumes can cause serious injury or death if inhaled. Wear a respirator
as recommended by the fluid and solvent manufacturer’s Safety Data Sheet.
TOXIC FLUID & FUMES
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in
the eyes or on the skin, inhaled, injected or swallowed. LEARN and KNOW the
specific hazards or the fluids you are using.
FIRE AND EXPLOSION HAZARD
Improper equipment grounding, poor ventilation, open flame or sparks can
cause a hazardous condition and result in fire or explosion and serious injury.
MEDICAL ALERT
Any injury caused by high pressure liquid can be serious. If you are injured or
even suspect an injury:
Go to an emergency room immediately.
Tell the doctor you suspect an injection injury.
Show the doctor this medical information or the medical alert card
provided with your airless spray equipment.
Tell the doctor what kind of fluid you were spraying or dispensing.
GET IMMEDIATE MEDICAL ATTENTION
To prevent contact with the fluid, please note the following:
• Never point the gun/valve at anyone or any part of the body.
• Never put hand or fingers over the spray tip.
• Never attempt to stop or deflect fluid leaks with your hand, body, glove
or rag.
• Always have the tip guard on the spray gun before spraying.
• Always ensure that the gun trigger safety operates before spraying.
It is the of the to this to the of the
For see the
PINCH POINT HAZARD
Moving parts can crush and cut. Pinch points are basically any areas where
there are moving parts.
CAUTION ! WARNING !
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2. Description:
The Binks E420 is a lightweight high-pressure nozzle applicator designed for robotic applications, with
high precision and quality demands. The applicator is equipped with a swivel for optimum robot flexibility.
The swivel makes it possible for the robot to rotate the nozzle head independently of the cables and hoses
supplying the applicator.
Due to its flexibility, the Binks E420 is designed for applications: Underbody coating (UBC), Underbody
seam sealing (UBS), and Interior seam sealing (ISS).
The Binks E420 is designed to handle most types of single component adhesives and sealants with
medium to high viscosity.
The solenoid valves operating the pistons for the material valves are mounted externally for easy
maintenance.
Material circulation is provided through the entire length of the applicator for material thixotropic
breakdown and temperature control.
If required, the following optional features can be added to the basic configuration of the applicator:
• Connection housing with PT100 temperature sensor and pressure sensor.
Main parts:
Connection housing
Cylinder assembly
Nozzle head
Swivel housing
Central body Extention
Central body Axis
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2.1 Central body:
The Binks E420 applicator central body contains these main parts:
The central body has two main parts which are the extension (1) and the axis (2). The two parts are
mounted together with the help of two rings (3) which also act as a lock ring for the swivel housing.
Inside the central body axis are packing sets (4) that seal off the needles from material pressure.
1
2
3
4
4
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2.1 Central body:
The central body connects material and air to the nozzle head and the cylinder block, respectively.
Two parallel channels supply material up to the nozzle head. A third channel is provided for the material
return flow back to the swivel housing. When a version of the applicator without circulation is used material
is supplied through all three channels in the central body.
Channel arrangements in the central body:
Product in
Product Return
Product in
Air signals
Material return channel
Material inlet channel
Material inlet channels
Material return channel
Air channel
Air signals
Material return channel
Nozzle 3
Material inlet channel
Nozzle 1
Material inlet channel
Nozzle 2
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2.2 Swivel housing:
The swivel housing supplies the material from the connection housing to the central body and the cylinder
unit. The swivel housing consists of three main parts which are the material chamber (1), the air chamber
(2), and the solenoid valves (3). The external solenoid valves supply compressed air to the cylinder unit.
There is one inlet channel (5) and one return channel (6) in the material housing. In case no circulation is
used both are used as inlet channels. Note also the drainage holes (7) that connects to the front and back
drainage chambers.
The internals of the material chamber differs depending on if circulation (8) is used or if no circulation (9) is
required. The extra seal ring (10) allows for full circulation up to the nozzle head of the applicator.
1
2
3
5 6
7
9 8
10
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2.2 Swivel housing:
To keep the swivel housing centered on the central body ball bearings are used, one in the material
chamber (1) and one in the air chamber (see page 10).
There is a front (2) and a back (3) drainage chamber in the swivel chamber that are both sealed by
additional seals (4) to prevent material leakage into the air chamber and onto the car chassis.
Note the material inlet (5), material return (6), and drainage channels (7) in the swivel housing.
The internal chamber rings are all locked in place by interconnecting pins (8) which are locked to the inside
of the material chamber (9) with one pin (10).
2 3
1
4 4
8
8
9
10
7 6 5 7
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2.2 Swivel housing:
The pistons are actuated by three monostable 3/2 solenoid valves (1) that are attached to the air housing.
They are easily removed and replaced during production, without dismounting the applicator from the
robot, should they fail.
An 8 mm coupling (2) that is connected to the air chamber supplies the solenoids with compressed air.
From the solenoids, compressed air is supplied to the central axis through the air distributor ring (3).
1
3 2
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2.3 Connection housing:
The connection housing is designed as the common platform for all external connections to the Binks E420
applicator.
The connections for material supply (1) and return (2) are placed in the upper connection piece. The Basic
version of the applicator only uses a single nipple (3).
For aluminium applicators, the nipples and gaskets are all internal 3/8 BSP.
The connection housing may also include a PT100 temperature sensor (4) in the material inlet and a
pressure transducer (5) in the material return channel. When spraying there is no return flow, the pressure
in the return line is equal to the pressure just before the nozzle head.
The connection housing uses either an 18-pin connector (6) or a 5-pin connector (7).
All internal cabling is handled by plug and pull connectors (8) for easy maintenance.
5
1
2
4
Connection housing with PT100 temperature
sensor and pressure sensor
Connection housing without sensors
3
Unless the pressure or temperature sensors are malfunctioning they
should NOT be removed from the lower connection housing. Removing or
cleaning either of the sensors may damage them and cause them to
malfunction.
CAUTION !
6
7
8
8
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2.4 Nozzle head:
The nozzle head comes in a variety of different designs depending on the material and method of
application used.
The nozzle heads are designed to accommodate guided nozzles with standard measurements.
Standard nozzle head
Square adapter Square adapter and rectangular nozzle head
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2.5 Cylinder assembly:
The main part of this assembly is the cylinder block (1) which has three pneumatic cylinders that operate
the material valves. In each of the cylinders, a piston (2) is fixed to the valve needle. On top of the cylinder
block is a cylinder cover (3) fitted that includes springs (4) that close the material valves. The cylinders are
actuated by 24 V monostable 3/2 port solenoid valves.
1
4
3
2
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2.6 Swivel locking bracket:
Connected to the swivel housing is the swivel locking bracket, that locks the swivel housing and the
connection housing to a fixed point between axis 5 and 6 on the robot. This design makes sure that the
connections follow the motion of axis 5. Only the central body follows the motion of axis 6.
The swivel lock depends on the make and model of the robot manufacturer.
Depending on robot type the swivel lock might have to be aligned to the 5th axis of the robot using a
calibration tool.
The image shows an example of a swivel lock
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2.7 Mounting flange:
The mounting flange (1) is the interface between the Binks E420 applicator and the sixth axis of the robot.
Consequently, the design of the mounting flange is robot and manufacturer-dependent.
The flange is fixed to the robot using screws (2) where the guide pin (3) locks the flange in position on the
robot`s sixth axis. With the flange fixed to the robot, the applicator is mounted on the flange and fixed in
position by two guide pins, one that centers the applicator (4) and one locating pin (5).
The applicator is then mounted onto the mounting flange using the three M6 (6).
6
1
3
5
2
4
The image shows an example of a mounting flange
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2.8 Tools:
Standard tools needed for service of the Binks E420 applicator:
• 2 mm Hex key
• 2.5 mm Hex key
• 3 mm Hex key
• 4 mm Hex key
• 5 mm Hex key
• 7 mm Wrench
• Philips screwdriver (PH1)
It is recommended to use the special tools kit for the E420 (sold separately).
Part no. 6004 0803 00.
The special tools kit contains:
6004 0802 00 6004 0802 03
6004 0154 11 6004 0154 10
Not using correct tooling might void
warranty
CAUTION !
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3. Installation instructions:
To ensure a trouble free operation of the Binks E420 applicator it is very important that the unit is
properly installed on the robot. It is also very important that the function of the applicator is carefully
checked before start up.
Installation of the Binks E420 applicator
Following parts are normally required:
1 piece. Binks E420 applicator with nozzle head and nozzle cap.
1 piece. Robot mounting flange.
1 piece. Swivel locking bracket.
1 piece. Cable with 5-pin or 18-pin connector (other configurations possible).
3 piece. Nozzles
(See accessories list 9836 4139 02 for available options)
Before starting installation of the Binks E420
applicator, always read chapter 2: Descrip-
tion, in order to be familiar with the various
parts of the applicator.
NOTE
Be especially careful when connecting the
high pressure material supply system and
always keep clear of the nozzles when test
spraying.
WARNING !
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3. Installation instructions:
Before installing the nozzles, it is important to check that the nozzle packings are in their correct positions
(1).
Fasten the mounting flange to the 6th axis of the robot using the 6 screws with low heads (2), make sure
the pin (3) is in the correct position. Align the applicator with the two pins (4) in the mounting flange and
then fasten the applicator using the three screws (5). Use the markings to align the applicator and the
flange (6).
1
1
4
4
3
2 [5 Nm]
4
5 [6.5 Nm]
6
The mounting flange and the swivel lock are
only for illustration. Both are depending on
the robot manufacturer and type.
NOTE
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Mount the block (1) to the plate using the two
screws (2) note the two guide pins (3).
Mount the swivel lock applicator bracket (4) with
the two screws (5).
Guide the robot bracket (6) into place in the sliding
block (7) then fasten it with the two screws (8).
3. Installation instructions:
The next step in installing the applicator is the swivel locking bracket. The installation instructions on this
page show how to install the standard swivel locking bracket. (instructions are shown with an ABB robot
and the mounting flange and swivel lock are for illustration purposes)
1
3
2 (6,5 Nm)
4
5 [6.5 Nm]
6
8
[6.5 Nm]
7
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3. Installation instructions:
When the applicator is fixed in the correct position the electrical cables can be connected. First, connect the
cable to the applicator, then install the cable to the robot and make the appropriate connections in the
control cabinet.
The air supply is connected to the applicator with an 8 mm PU-hose to the push-in coupling on the side of
the swivel housing (1).
The material supply hose is connected to the connection point Inlet (I). The material return hose is
connected to the connection point Return (R). If circulation was not selected, the applicator only has the
inlet nipple.
After completion of the installation of hoses and cables, their free movement must be checked by moving
the fifth axis of the robot. The hoses and cables must be able to move freely without stretching or
scratching the robot arm.
1
I
R
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3. Installation instructions:
With the applicator properly installed on the robot, the functions of the unit can be tested. First, open the
air supply. There must be no sound from leaking air.
Check that the solenoid valves are working properly by open and closing each valve from the robot
pendant and listen to the sound of the piston in operation.
Apply material supply pressure and check for leakage.
Move the applicator to the purge position and purge all nozzles one by one until the unit is filled up with
material and all entrapped air is removed from the supply system.
Open the circulation valve and purge the material through the dump valve until all entrapped air in the
material return is removed.
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4. Dismounting instructions:
Disconnect the material inlet hose (1) and the material return hose (2). Always use two wrenches when
loosening the high-pressure hose connection.
Disconnect the air hose (3) and unplug the electrical connector (4) by pulling the cable connectors
backward from the gable.
Unscrew the two screws (5) that fix the swivel locking bracket to the applicator and prevent the swivel
housing from rotating. A swivel lock for an ABB robot is shown below.
1
2
3
4
Clean the unit and all parts surrounding it
before removing the applicator.
NOTE
Before any service or cleaning action is
undertaken on the applicator make sure that
air and material pressures are relieved!
WARNING !
5
The mounting flange and the swivel lock are
only for illustration. Both are depending on
the robot manufacturer and type.
NOTE
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4. Dismounting instructions:
Unscrew the three screws (1) holding the applicator to the mounting flange. The screws can be left in the
cylinder housing due to their design (2).
With the applicator removed from the robot disassembly and service can be performed.
Be sure to store all removed parts in a safe place.
1
1
2
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5. Disassembly instructions:
Disassembly starts with removing the nozzle head. For the standard head, remove the screw (1) for the
nozzle cap, make sure not to lose the nozzles. Then unscrew the three screws (2) that hold the
nozzle head to the central body and remove it. Remove the nozzle seals (3) from the nozzle head.
For the rectangular head, start with removing the nozzle head (4) from the adapter by unscrewing the four
screws (5). Alternately unscrew the three screws (6) holding the adapter to the central body then remove
the adapter. The nozzles can be removed from the nozzle head by unscrewing the two screws (7) holding
the nozzle plate (8) to the nozzle head. Nozzle seals (9) and adapter seals (10) can be removed.
1
2
Be sure to store all removed parts in a safe place.
Immediately clean all parts after removal that will be fitted again and inspect
the cleaned parts for damage and excessive wear and replace if so necessary.
It is recommended to use the special tools kit for the E420, see page 16.
NOTE
Ensure a proper work bench with a vice with
soft jaws and that access to compressed
air is available to facilitate the work. Do not
fasten the central body on the sleeve.
CAUTION !
5
4
6
7
8
3
9
10
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
Fasten the applicator to a vice with soft jaws (1) then unscrew the three screws (2) and remove the
cylinder cover (3) and the springs (4).
Remove the seal (5) then push the needles or pull the pistons to a position where you can access the
screws (6) that holds the pistons to the needles. Loosen the two screws (7) that hold each piston to its
needle and remove the piston (8) from the needle. Remove the seal (9) and the guide rings (10) from the
piston (8).
2
Always use a vice with soft jaws.
NOTE
3
4
1 1
5 6
7
8
10 9
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
The needles can now be pushed to the bottom of the cylinder (1) and pulled out from the central body (2).
To separate the central body extension from the central body axis start with unscrewing the three (3)
screws holding the two pieces of the lock ring together. This will allow you to remove one piece of the lock
ring (4) but also the central body extension (5).
1
2
3
4
5
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
Remove the three O-rings (1) then unscrew and remove the second piece of the lock ring (3).
Separate the central body axis and cylinder block from the swivel housing by first rotating (4), then pull it
out (5). Important! If the central body axis is stuck, use a soft hammer or a tool with soft ends to get it
out, make sure not to damage the cutouts for O-rings and the pin(6).
1
2
4
5
6
The surface with cutouts for o-rings on the
central body axis is fragile.
Do not use a tool to hammer on this fragile
area.
CAUTION !
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
With the central body axis (1) taken out from the swivel housing unscrew the three screws (2) holding the
cylinder block (3) to the axis (1). Remove three seals (4) and three O-rings (5) from the back of the
cylinder block.
Pull out the upper needle guides (6), the top hole of the needle guides is threaded, and an M4 screw can
be used as a tool. Remove the seal (6) and the O-ring (7) from the three needle guides.
1
2
3
4
5
5
8
7
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5. Disassembly instructions:
Pull out the plastic distances (1) then the three distances (2) from the central body axis, tool 6004 0154 11
can be used (see page 16). Remove the seals (3) and O-rings (4) from the distances. The central body
parts have all been disassembled and can be cleaned appropriately.
The bracket for the swivel lock can be removed by unscrewing the four screws (5) holding the bracket (6)
to the air housing. Then remove the bracket (6), the two pins (7) can also be removed.
Be sure to store all removed parts in a safe place.
1
2
4 3
5
6
6
7
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
Unscrew the four screws (1) holding the cover (2) to the swivel housing and slide it off. Unplug the cable
(2) to the solenoid valves.
Unscrew the four screws (3) holding the connection housing (4) and swivel housing (5) together, then
separate them.
1
2
3 3
5
4
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
Version without circulation and sensors:
Unscrew the four screws (1) and remove the
connector and plate (2), the cable bridge (3) to the
solenoids can be disconnected from the connector (4).
If need be the plug (5) and push-in elbow coupling
(6) can be removed for easier access to the drainage
channel.
Version with circulation and sensors:
Unscrew the four screws (7) holding the connector
plate (8) to the connection housing. Unplug all the
push and pull connectors (9) from the connector.
Be careful when removing the connector plate to
avoid damaging the cables and connectors for the
sensors.
1
7
3
2
6
5
To avoid damages to the sensor cables use
caution when removing the connector and
plate.
NOTE
8
9
4
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
Unscrew the four screws (1) holding the upper connection
(2) housing to the lower connection housing (3). The
upper connection housing can be pulled off the lower.
Two O-rings (4) are used to seal the material channels
between the two parts and the two pins (5) help guide the
part when they are assembled.
If need be the plug (6) and push-in elbow coupling (7) can
be removed for easier access to the drainage channel.
The nipples (8) can be removed and exchanged should it
be needed.
2
3
5
4
Unless the pressure or temperature sensors are malfunctioning they
should NOT be removed from the lower connection housing. Removing or
cleaning either of the sensors may damage them and cause them to
malfunction.
CAUTION !
6 7
8
1
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
Remove the O-rings for the material (1) and the drainage (2) channels. Unscrew the six screws (3) for the
solenoid valve block (4) and remove the 3 solenoids with the solenoid valve connector.
The connector can be removed by loosening the three
screws (5) if the solenoids need to be changed or service is
required.
Unscrew the four screws (6) holding the material housing
(7) and the air housing (8) together, and separate the two.
2
1
4
3
5
6
7
8
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
For the next part of the disassembly special tools 6004 0802 00 (1) and 6004 0802 03 (2) are
recommended for easy disassembly.
Align the pins and the corresponding holes (3) in both the air housing (4) and the tool (5). When the air
housing (4) has been placed in the tool (5) press the air distributor ring (6) out of the air housing using the
pressing tool (7). A vice with soft jaws can be used to help with pressing out the air distributor ring.
Take out the four seals (8) from the inside of the air distributor ring after it has been removed.
5
3
3 7
8
4
5
1
2
4
6
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
Pull out the four O-rings (1) from the air housing (2). The air coupling (3) can also be removed and
exchanged if necessary.
For removal of the sealing package, tool 6004 0802 03 needs to be used, see page 16.
Begin with placing the tension tool (4) into the cutout (5) in the cup tool (6). Place the material housing (7)
on top of the two tools, align the pins (8) with the holes for the screws. Note the orientation of the material
housing (7) and the cup tool (6).
1
2
3
4
5
7
8
8
6
6
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
Use the tension tool clamp (1) and screw it onto the screw (2) to expand the tension tool (3) so that it gets
fastened to the material distribution ring. Screw the tension tool clamp (1) down by using hand force or a
flat screwdriver, note the approximate height over the material housing (4).
The cup tool (5) is then moved to the other side of the
material housing (6), note the orientation. Align the pins (7)
with the holes for the screws.
3
1
2
4
7
7
5
5
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
The material seal package is then pressed out of the materials chamber with the use of a vice. Place the
tool sides (1) at each jaw of the vice and tighten the vice to press out (2) the material seal package.
Important! Do not use a hammer or any other tool to force the sealing package out of the material
chamber. A controlled linear force is needed to avoid possible damages to the material seal package and
material chamber.
When the material seal package (3) has been fully pressed out the parts and tools can be separated by
pulling of the swivel housing (4) and unscrewing the tension tool clamp (5).
A vice is required for the disassembly of the
material seal package from the material
housing.
CAUTION !
1
1
2
3
4
5
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
When the material seal package has been removed from the swivel housing all the material seals (1) and
v-seal (2) can be removed.
With the material seal package taken out from the material chamber remove the four O-rings (3) and the
v-seal (4) from the material housing (5).
1
1
2
1
1
1
2
Material seal package with circulation
Material seal package witout circulation
3
4
5
5
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Be sure to store all removed parts in a safe place.
5. Disassembly instructions:
All the parts that are going to be reused in the assembly need to be cleaned.
This cleaning process differs depending on the material of the part and application material.
All parts included in the applicator should also be inspected for damages that can affect the lifetime of the
part itself or other parts that it is in contact with.
Should the part be damaged it needs to be replaced.
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6. Assembly instructions:
The assembly of the applicator starts with the connection housing. In case they have been removed,
reattach the pressure (1) and temperature (2) sensors to the lower connection housing (3), the pressure
sensor (1) should be tightened to 10 Nm and the temperature sensor (2) to 20 Nm, as well as the plug (4)
and the push in elbow coupling (5).
Place the O-rings (6) in place in the upper connection housing (7) and using the four screws (8) fasten it to
the lower connection housing (3).
Connect all the internal cables, for the pressure and temperature
sensor (9) should the applicator have it and the cable bridge for
the solenoids (10), to the connector (11). When all the cables
have been properly connected fasten the connector and plate
(12) onto the connection housing using the four screws (13).
Before assembly, make sure all spare parts are available (new in
unopened package if so delivered), other parts thoroughly cleaned.
It is recommended to use the special tools kit for the E420, see page
16.
NOTE
5
1 [10 Nm]
4
2 [20 Nm] 3
3
6
7
8 [6,5 Nm]
9
10
11 12
13
Ensure a proper work bench with a vice with soft jaws. Suitable
lubricant and thread locking compound should also be available.
Recommended tightening torques:
Pressure sensor 10 Nm
Temperature sensor 20 Nm
CAUTION !
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6. Assembly instructions:
Before the connection housing is attached to the swivel housing it needs to be fully assembled.
Mount the v-seals (1) in the material housing (2) and the leakage distributor (3) ring.
Mount the material seals (4) into the material distributor rings (5). For mounting the seals, tools with article
number 6004 0802 00 are used, see page 16. Place the seal mounting tool (6) on top of the material
distribution ring (5) then place a seal into the seal mounting tool (6) and mount it into the material distance
ring by pressing it into position using the pressing tool (7). Lightly lubricate the inside (8) of the seal
mounting tool for easier mounting of the material seal rings.
There are two material seal rings for the version without circulation and three for the version with full
circulation, see page 38.
1
1
2
3
4
5
5
6
4
7
8
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6. Assembly instructions:
Mount the O-rings (1) in the material housing.
Assemble the material seal package, note the guide
pins between the different material rings. There are
two pins between the material chamber rings (2),
three (3) that guide the air distributor ring, and one
(4) that prevents rotation of the material seal
package.
Lightly lubricate the inside of O-rings (1) when they
are mounted in the material chamber and the
outside of the material seal package (5).
Place the material seal package at the top of the
material chamber, align the pin (6) with the cutout
(7) in the swivel housing. Put the parts between the
jaws of the vice then tighten the vice to press the
material seal package into place.
The material seal package can be rotated to align
the pin (6) and the cutout (7) when it is almost fully
pressed in.
1
4
2
2
3
6
7
Ensure a proper work bench with a vice with
soft jaws.
CAUTION !
6 7
5
5
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6. Assembly instructions:
Mount the four O-rings (1) inside of the air housing
(2), reattach the air coupling (3) if it has been
removed. Mount the four seals (4) inside the air
distributor ring (5).
Lightly lubricate the inside of the O-rings (1) and the outside of the air distributor ring (5). Place the air
distributor ring (6) on top of the material seal package, use the pins (7) and corresponding holes (8) for
correct alignment. Align the air housing pins (9) with the holes (10) in the material housing.
1
3 4 5
Ensure a proper work bench with a vice with
soft jaws.
CAUTION !
7
6
8
9
10
2
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6. Assembly instructions:
When the air housing (1) is placed on top of the air distributor ring and properly aligned with the material
housing (2) a vice with soft jaws is used to press the two together.
After pressing the internal parts in position fasten the air housing and the material housing together with
four screws (2).
Attach the three solenoids (1) to the connector (2)
and tighten the 3 screws (3).
Align and fasten the solenoid valves to the air housing
(4) using six screws (5).
1
Ensure a proper work bench with a vice with
soft jaws.
CAUTION !
2
2 [6.5 Nm]
4
1
5
[1.35 Nm]
2
3
[1.35 Nm]
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6. Assembly instructions:
Place the two O-rings for the material channels (1) and
the drainage channels (2) in place on the swivel
housing.
Mount the connection housing to the swivel housing
with the two screws in the front (3) and the two
screws in the back (4).
Plugin the cable bridge connector (5) into the header
(6) for the solenoid valves.
The connection housing and the swivel housing have been assembled and mounted together. They can be
put to the side and assembly of the central body and its parts need to be done next.
1
3 [11,1 Nm]
2
4
[6.5 Nm]
5
5
6
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6. Assembly instructions:
Begin the assembly of the central body axis by mounting the needle seals (1) and the O-rings (2) to the
distance pieces. Press the seals (1) in place using a clean flat surface, then check to make sure that the
seal is flush against the edges of the distance piece.
There are a total of 6 of each seal and O-ring that are mounted to the different distances. Note the
difference between the needle guides for the inlet (3) and return (4) channels.
Lightly lubricate the O-ring (5) before mounting the needle guides in the central body axis (6). Mount the
distance rings (7) in place. Lightly lubricate the O-rings (8) then mount the upper needle guides (9) into the
central body axis (6). Tool 6004 0154 10 can be used to push the parts in place, see page 16.
2 2
1 1
5
6
3 4
5
7
7
8
8
6
9
9
9
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6. Assembly instructions:
Before the central body axis is mounted to the cylinder block (1) the seals (2) and O-rings (3) need to be
mounted into the cylinder block (1).
To mount the seals (2) special tool 6004 0154 10 (4) and 6004 0154 11 (5) needs to be used. Place the
seal (2) on a flat surface then push the seal (2) in place in the tool, note the cutout (6) on one side of the
tool and the correct direction (7) of the seal.
Place the tool (4) over the position of the seal then push the seal (2) into position with the tool (5).
Make sure that the two pins (8 & 9) are in their correct position or place them in position if they have come
loose during disassembly.
1
3
2
8 9
4
5
2
4
6
<
<
7
1
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6. Assembly instructions:
The cylinder block (1) is then fastened to the central body axis (2) with three screws (3).
Use pins (4 & 5) in the cylinder block and the corresponding
holes in the central body axis (6 & 7) to guide the two parts to
the correct mounting position.
With the cylinder block (1) mounted to the central body axis (2) it
can be installed into the swivel chamber. Lightly lubricate the
seals (8) inside the swivel housing and the outside of the central
body axis (9).
3 [6.5 Nm]
6
7
8
2
9
4
5
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6. Assembly instructions:
Fasten the assembled connection housing and swivel housing in a vice with soft jaws (1). Place the two
pins (2) in place in the air housing should they have been removed.
Place the bracket (3) in place guided by the two
pins (2). Mount the bracket (3) to the air housing
using the four screws (4).
1 1
Always use a vice with soft jaws.
NOTE
2
4
3
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6. Assembly instructions:
The central body axis is then inserted into the material chamber and pressed (1) into place. Rotate the
central body axis (2) whilst applying pressure for easier installation.
With the central body axis installed in the swivel chamber screw on the lock ring (3) to hold the central
body axis in place and place the three O-rings (4) into their grooves. Mount the pin (5) should it have been
removed.
1
2
3
4
5
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6. Assembly instructions:
With the central body axis secured in the swivel housing, the needles and pistons can be mounted
together. Start with lightly lubricating the back end (1) of the needle shaft. Then push the needles (2)
through from the front of the central body axis.
When the needle has been pushed through the piston can be
attached. Before the piston (3) is attached to the needle the
O-ring (4) and guide rings (5) needs to be mounted to it.
The piston (6) is mounted onto the needle and fastened with two
stop screws (7). Make sure that the needle is bottomed out in
the piston (8) so that the stop screws are fastened in the correct
position (9) on the needle.
1
2
5
4 3
6
7
[3.3 Nm]
7 [3.3 Nm]
8
9
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6. Assembly instructions:
Lightly lubricate (1) the O-ring and guide rings and the side of the piston housing (2) then push (3) the
piston into its bottom position (4) in the cylinder block. Repeat the steps on the previous and this page,
until this point, for all the needles and pistons.
With all the needles and pistons in place, the
central body extension (5) is mounted to the
central body axis.
The central body extension is fastened to the axis
using the ring attachment (6) and three screws (7).
Use the pin (8) and corresponding hole (9) to guide
the extension to its correct position.
1
3
2 4
5
6
7
8
9
6
7
[3.3 Nm]
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6. Assembly instructions:
Place the nozzle head seal (1) in its groove at the top of the central
body extension.
Guide the round nozzle head (2) to its correct position using the
pins (3) and corresponding holes (4) then fasten the nozzle head
with three screws (5).
For the square adapter (6), guide it using the pins (3) and corresponding holes in the adapter (7). The
adapter is then fastened to the central body with three screws (8). After placing the seals (9) in place a
nozzle head (10) can be attached to the square adapter (6) using four screws (11).
1
4
4
5 [3.3 Nm]
2 3
3
3
6
8 [3.3 Nm] 9 10
11 [3.3 Nm]
3
7
7
3
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6. Assembly instructions:
Place the springs (1) into the pistons.
The cylinder cover (2) is then placed on top of the
springs and mounted to the cylinder block with three
screws (3), which are tightened alternately.
Slide the protection cover (4) over the central body
extension and in place on the swivel housing then use
four screws (5) to fasten it.
1
2
3 [3.3 Nm]
4
5 [1.35 Nm]
5
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6. Assembly instructions:
Place the three nozzle seals (1) in place in the cutouts in the nozzle head (2). The nozzles (3) are slotted
into the nozzle head cap (4) which is fastened to the nozzle head using one screw (5). When mounting the
nozzle cap to the nozzle head make sure that the nozzles do not fall out.
For the square nozzle head (5), put the seals (6) in place. Then slot the nozzles (3) into the nozzle plates
(7) and fasten the plates to the nozzle head using two screws (8).
The applicator is now fully assembled and should be tested to ensure correct assembly.
1
2
4
3
3
5 [11,1 Nm]
6
5
3
7
8 [3,3 Nm]
3
3
7
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6.1 Testing before installation:
If the applicator has been assembled after a major repair or maintenance operation, it is recommended to
do a function test before the applicator is returned to production.
The extent of the test is dependent on the degree of maintenance performed on the applicator and the
available test facilities.
A minimum level of function test is to connect the compressed air supply, checking for air leakage by
opening each of the solenoid valves manually.
The electrical connections can be checked using an ohm-meter to test the connections from the plug to the
terminals and to make sure that there are no short circuits.
Make one last check on all fasteners and then follow the installation instructions (Chapter 3, page 17) to
mount the applicator on the robot.
If the applicator is tested off-line with
material pressure applied it’s very important
to take appropriate safety measures to
prevent personal injury!
WARNING !
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7. Technical specifications:
Torque requirement Nm
M3 1.35
M4 3.3
M5 6.5
M6 11.1
E420
Weight - Basic
Weight - Circulation
Approx. 3.4 kg
Approx. 3.7 kg
Length 469.9 mm
Swivel height - Basic
Swivel height - Circulation
172.8 mm
201.8 mm
Mounting arrangement Robot mounting flange
Max working pressure 250 bar
Max working temperature 80° C
Material inlet Male 3/8 BSP connector
Material return Male 3/8 BSP connector
Air ports 8 mm
Minimum air pressure requirement
Maximum air pressure
5.5 bar
7 bar
Material leakage port 8 mm
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8. Dimensions:
Basic connection housing, without circulation
Round nozzle head
Temperature and Pressure connection housing, with circulation
Round nozzle head
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8. Dimensions:
Temperature and Pressure connection housing, with circulation
Square nozzle head
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9. Maintenance:
To ensure top performance, it is very important to maintain the unit properly. This chapter describes the
minimum level of daily, monthly and preventive maintenance.
Daily maintenance
Check the applicator for material leakages by ocular inspection.
Check the leakage detection hole on the connection housing and all connections.
Listen carefully for air leakages.
Clean the applicator thoroughly.
Monthly maintenance
All of what is mentioned in daily maintenance
Inspect hoses and cables for excessive wear.
If possible, run a spray test on a spray test table.
Preventive maintenance
Typical wear parts in the applicator are the sealing rings inside the swivel chamber, the central body, the
needles, needle packings, and the needle seats. Refer to the spare parts manual for additional information
and spare parts numbers.
The wear of these parts is very dependent on the sealer material being used and also depending on the
operation conditions of the applicator.
Due to this, the frequency for preventive maintenance has to be evaluated for each case of application.
Refer to the service interval instruction manual for additional information.
Maintenance frequency
Due to the variations in working conditions, it is not possible to give a general frequency for preventive
maintenance.
The figures below can thus only be used as guidance for the maintenance frequency and are best
estimates based on standard material.
If a normal PVC material and supply pressure are used, it is recommended that the needle packings should
be replaced after 1 000 000 cycles [1 cycle = open and close].
The Sealing rings in the swivel chamber is expected to be changed after 2 000 000 rotation cycles
[1 cycle = start to stop].
Preventive maintenance service
Dismount and disassemble the Binks E420 applicator according to chapters 4 and 5.
Clean all parts thoroughly and make sure no parts are damaged or worn out. Replace all parts included in
the service kits. Please refer to the spare parts list for available service kits.
After reassembly of the applicator, test all functions of the applicator to make sure that all parts are
installed correctly.
Before any service action is undertaken on
the applicator, make sure that air and
material pressure is relieved.
WARNING !
Always use original spare parts!
NOTE
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