- E415 Gun Manual 9836 4173 01 [ English ]
EN
SERVICE MANUAL
www.Binks.com
Binks E415
Swiveling applicator for Robotic
Sealing Applications
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
2 / 59
1. Safety information ................................................................... 3
1.1 Warnings ............................................................................. 4
2. Description ................................................................................ 5
2.1 Central body ......................................................................... 6
2.2 Swivel housing ....................................................................... 7
2.3 Connection housing ............................................................... 9
2.4 Nozzle head ........................................................................ 11
2.5 Cylinder assembly ............................................................... 12
2.6 Solenoid valves .................................................................... 13
2.7 Swivel locking bracket .......................................................... 14
2.8 Mounting flange .................................................................. 15
2.9 Optional equipment .............................................................. 16
3. Dual material and Dual process ............................................ 18
4. Installation instructions ........................................................ 19
5. Dismounting instructions ....................................................... 27
6. Disassembly instructions ........................................................ 29
6.1 Optional equipment disassembly instructions .......................... 39
7. Assembly instructions ............................................................ 40
7.1 Optional equipment assembly instructions .............................. 52
7.2 Testing before installation ..................................................... 54
8. Technical specifications .......................................................... 55
9. Dimensions ............................................................................. 56
10. Maintenance ........................................................................ 58
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:
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
3 / 59
1. Safety Information
Thank you very much for choosing the Binks E415 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 application. 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 E415 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 E415 applicator.
To prevent any personal injury or equipment damage, make sure that the maximum operating
pressures are not exceeded.
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
4 / 59
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 !
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
5 / 59
2. Description:
The Binks E415 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 E415 is designed for applications like: Underbody coating (UBS), Liquid
applied sound deadening (LASD) and seam sealing.
The Binks E415 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.
• Two heating rod elements and a PT100 sensor in the lance of the applicator. (only available for SS ver-
sion)
• Induction sensors for indication of needle opened/closed and actuation times.
• 4th valve with air swivel.
Main parts: Connection housing
Mounting flange
Cylinder assembly
Nozzle head
Lock ring
Swivel chamber
Air Swivel
(optional)
Central body
Additional sensors and
heat rods (optional)
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
6 / 59
2.1 Central body:
The Binks E415 applicator central body contain these main parts:
A needle guide is located at the front end of the central body to align the needle valves with the valve seats
in the nozzle head. The nozzle head gasket seals between the material supply and the nozzle head. The
two nozzle head locating pins ensure that the nozzle head is always mounted in the correct position.
Valve needles packing sets. The packing sets seal off the valve needles from material and air pressure.
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
7 / 59
Product in
Return
Product in
Air signals
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.
Channel arrangements in central body:
Material return channel
Material supply channels
Nozzle 1
Nozzle 2
Nozzle 3
Material inlet channel
Material return channel
Air channel
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
8 / 59
2.2 Swivel housing:
The swivel housing supplies the material from the connection housing to the central body and the
cylinder unit. External solenoid valves supply compressed air to the cylinder unit.
The material supply includes normally two channels (1), one for the material supply, the other for the
material return. The return channel is in the front end of the swivel housing. The two channels are
separated by a sealing distance ring.
When using the applicator for two different materials, the supply and return channels are sealed off by
using a seal ring between the two channels.
If the applicator is used in an application without material circulation, the two material channels are joined
to one, supplying material through all three channels in the central body.
At both sides of the swivel chamber a bearing (2) ensures that the swivel chamber is always in a centered
position on the central body.
The distance ring (3) in front of the leakage hole is located between the channels for material and air.
All sealings and distance rings are locked in place by the bearing housing (4) at the rear end of the swivel
chamber.
2
3
1
2
4
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
9 / 59
2.3 Connection housing:
The connection housing is designed as the common platform for all external connections to the Binks E415
applicator.
The connections for material supply (S) and return (R) are placed in the upper connection piece. For
aluminium applicators the (R) nipple, (S) nipple and gaskets (1) are all internal 3/8 BSP. See next page for
stainless steel version.
The base module may also include a PT100 temperature sensor (2) in the material inlet and a pressure
transducer (3) 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 is connected with either one 18-pin connector (4) or 2 connectors, one 14-pin and
one 8-pin connector. (see next page for 2 connector variant)
3
S
4
R
1
2
Connection housing with PT100 temperature
sensor and pressure sensor
Connection housing without sensors
6
S
4
R
1
5
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 !
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
10 / 59
2.3 Connection housing:
For stainless steel the inlet (S) gasket and nipple is internal 1/2 BSP. Return (R) gasket and nipple or plug
is either 3/8 or 1/2 internal BSP.
The connection housing is connected with either one 18-pin connector or 2 connectors, one 14-pin (1) and
one 8-pin (2) connector. (cable for 4th valve (3), see optional equipment page 16)
Connection housing stainless steel without
sensors
Connection housing Stainless steel with
sensors, 2 connectors and 4th valve
S
R
R
S
2
1
3
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
11 / 59
2.4 Nozzle head:
The nozzle head comes in a variety of different designs depending of the material and method of
application used.
The nozzle heads are designed to accommodate guided nozzles with standard measurements.
Standard nozzle head
Adapter
Adapter and rectangular nozzle head
Nozzle head for SSD nozzles
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
12 / 59
2.5 Cylinder assembly:
The main part of this assembly is the cylinder block (1) which has three pneumatic cylinders that operates
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 mono stable 3/2 port solenoid valves.
Inductive sensors (5), PT temperature sensor (6) and heating elements (7) is an optional part of this
assembly.
1
4
3
2
5
6
7
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
13 / 59
2.6 Solenoid valves:
The external solenoid valves (1) controlling the product valves are easily accessible under the cover (2).
The position of the valve controlling which needle is show below.
1
2
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
14 / 59
2.7 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.
Depending on robot type the swivel lock might have too be aligned to the 5th axis of the robot using a
calibration tool.
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
15 / 59
2.8 Mounting flange:
The mounting flange (1) is the interface between the Binks E415 applicator and the sixth axis of the robot.
Consequently the design of the mounting flange is robot dependent.
The flange is fixed to the robot using screws (6) where the guide pin (4) locks the flange in position on the
robots sixth axis. With the flange fixed to the robot, the applicator is mounted on the flange and fixed in
position by two guide pins (3) and three M6 screws (5).
1
5
4
2
3
6
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
16 / 59
2.9 Optional equipment:
Additional inductive sensors (1) for needle actuation times can be fitted in the cylinder cover (2).
If the material applicated is thermal sensitive, two heating rods (3) and a PT100 temperature sensor (4)
can be added to the central body. (only available for SS versions)
Electrical signals for these components are handled by slipring disks in the swivel housing (5) and central
body (6).
2
3
4
5
6
1
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
17 / 59
2.9 Optional equipment:
A 4th valve (1) with an air swivel (2) can be added if air is required at the nozzle head.
1
2
2
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
18 / 59
3. Dual material and Dual process:
Binks E415DM (Dual Material)
The Binks E415DM has 2 material inlets. The 2 materials come together in the nozzle head and all 3 nee-
dles can be used for both materials.
In case of circulation it is handled outside of the applicator.
If sensors are needed there is 1 temperature sensor for each material and 1 common pressure sensor for
both materials.
This applicator is mainly used for a production robot for 1 process like UBS or UBC but the different car
types gets different material and the customer wants to use all 3 nozzle for both materials.
The requirement are:
• Both materials (normally PVC) are chemically compatible.
• The application temperature is the same for both materials.
• There must be a material valve outside the applicator for each material to shut off if the other material
is being applied.
Binks E415DP (Dual Process)
The Binks E415DP has 2 material inlets and 2 material returns. Circulation goes through the material
connection block for both materials. If no circulation is needed the material inlet block only has 2 material
inlets.
The materials are completely separated. Needles 1 and 2 are used for material 1, needle 3 is used for
material 2.
If sensors are needed both temperature and pressure sensors are available for each material.
This applicator is mainly used for a production robot where 2 different processes like UBS and UBC
requires different materials and different type of nozzles and the customer wants to have the 2 materials
separate.
The requirement is:
• The application temperature is the same for both materials.
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
19 / 59
4. Installation instructions:
To ensure a trouble free operation of the Binks E415 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.
It is recommend using the tools supplied in the specific 415 tool kit (sold separately) for
convenience and correct fit, Part nr. 6004 0154 05
Installation of the Binks E415 applicator
Following parts are normally required:
1 pc. Binks E415 applicator with nozzle head and nozzle cap.
1 pc. Robot mounting flange.
1 pc. Swivel locking bracket.
1 pc. Cable with 18-pin connector (other configurations possible).
3 pc. Nozzles
(See accessories list (9836 4139 02) for available options)
Before the applicator is installed for the first time a calibration tool (part nr. 6004 0154 03)
must be used to align the swivel lock to the 5th axis of the robot.
The calibration toolbox contains the following:
1 pc. Calibration tool robot
1 pc. Calibration tool axis
3 pcs. Pin 6x12 mm
6 pcs. M6x12 mm hex socket screws
Follow the instructions on the next pages for the swivel locks that
requires a calibration. Make sure to position the 6th axis of the
robot in accordance to the type of swivel lock that is used.
If the robot bracket or frame is removed a recalibration is required.
Before starting installation of the Binks E415
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 !
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
20 / 59
4. Installation instructions:
Swivel locking bracket (6004 0154 54 and 6004 0154 95) (instructions are shown with a ABB robot)
Fasten the calibration tool on the 6th axis of the
robot.
Attach the robot bracket to the robot, do not
tighten the screws.
Do not tighten
Put the calibration tool for the axis in place without
forcing it and tighten the screw.
Tighten the screws on the frame.
Tighten the
screws
Remove the calibration tools. The swivel lock is
calibrated and the applicator can be installed.
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
21 / 59
Fasten the calibration tool on the 6th axis of the
robot.
Attach the frame to the robot, do not tighten the
screws.
Attach and fasten the robot bracket to the frame. Put the calibration tool for the axis in place without
forcing it and tighten the screw.
Tighten the screws on the frame. Remove the calibration tools. The swivel lock is
calibrated and the applicator can be installed.
Do not tighten
Tighten the
screws
4. Installation instructions:
Swivel locking bracket with frame (6004 0154 87 and 6004 0154 99) (instructions are shown with
a ABB robot)
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
22 / 59
4. Installation instructions:
Before installing the spray 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 and spacers (5).
1
1
2
3
4
4
5
4
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
23 / 59
Fasten the robot bracket to the robot. Hold the distance piece in place and put the swivel
locking bracket in place. Do not tighten the
screws for the plastic bearings.
Tighten the screws by the distance piece. Keep the
plastic bearing screws loose.
Apply hand pressure on the sides of the plastic
bearings to push them against the axis.
Tighten the
screws
Tighten the screws while still applying hand
pressure on the plastic bearings.
Do not tighten
The swivel lock is installed.
4. Installation instructions:
Next step in installing the applicator is the swivel locking bracket. The installation instructions on this page
and the two following shows how to install the standard swivel locking brackets. (instructions are shown
with a ABB robot)
Swivel locking bracket (6004 0154 95)
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
24 / 59
Fasten the frame to the robot.
Fasten the robot bracket to the frame. Hold the distance piece in place and put the swivel
locking bracket in place. Do not tighten the
screws for the plastic bearings.
Tighten the
screws
Tighten the screws by the distance piece. Keep the
plastic bearings screws loose.
Apply hand pressure on the sides of the plastic
bearings to push them against the axis.
Attach the last piece of the frame.
Do not
tighten
4. Installation instructions:
Swivel locking bracket with frame (6004 0154 99) (instructions are shown with a ABB robot)
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
25 / 59
4. Installation instructions:
Swivel locking bracket with frame (6004 0154 99)
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.
Tighten the screws while still applying hand
pressure on the plastic bearings.
The swivel lock is installed.
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
26 / 59
4. Installation instructions:
The air supply is connected to the applicator with a 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 return connection is
plugged.
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.
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 completely 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.
1
I
R
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
27 / 59
5. 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
backwards from the gable.
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 !
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
28 / 59
5. Dismounting instructions:
Unscrew the two screws (1) that fixes the swivel housing to the swivel lock bracket. Two different types of
swivel locks are shown below:
Unscrew the three screws (2) that mounts the applicator to the robot mounting flange.
Now the main parts of the applicator can be removed from the robot.
Be sure to store all removed parts in a safe place.
1
1
2
2
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
29 / 59
6. Disassembly instructions:
Disassembly starts with removing the nozzle head. For the standard head first remove the screw (1) for the
nozzle cap, make sure not to loose the nozzles. Then unscrew the three screws (2) that holds the
nozzle head to the central body and remove it.
For the rectangular head, start with removing the nozzle plate (3) for needle 1 to get axess to the screws
underneath. Unscrew the two screws (4 and 5) holding the nozzle head to the adapter and remove the
nozzle head. Alternately unscrew the two screws (6) holding the adapter to the central body then remove
the adapter.
1
2
3
4
6
5
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.
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 !
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
30 / 59
Be sure to store all removed parts in a safe place.
6. Disassembly instructions:
With the nozzle head removed from the central body, loosen the two screws (1) and slide the lock ring off
the central body. (2)
Remove the seal ring (3). Next step is to separate the central body with the swivelhousing. This is easiest
done by first fastening the connection housing or swivel housing in a vice with soft jaws (4). Then by use of
moderate force first rotate (5) and then push (6) the central body out of the swivel housing.
1
1
6
2
5
4
4
3
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
31 / 59
Be sure to store all removed parts in a safe place.
6. Disassembly instructions:
If an intermediate service is done the swivel housing and connection housing does not need to be taken
apart from each other. For a major service swivel and connection housing needs to be taken apart.
Unscrew the screws (1) holding the cover, four in total, and then remove it (2).
When the cover over the solenoid vales is removed the cables (3) can be unscrewed. To separate swivel
and connection house first unscrew and remove the connection housing covers (4). Then unscrew the four
screws (5) holding the two parts together.
1
2
3
4
4
4
5
5
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
32 / 59
Be sure to store all removed parts in a safe place.
6. Disassembly instructions:
All internal parts can now be removed from the swivel chamber. If need be, also the solenoid valves can be
detached. All internal gaskets and seals should be replaced if the swivel chamber is dismantled.
To get access to the components in the swivel housing start with unscrewing the four screws (1) that holds
the bearing housing (2) to the swivel chamber and then remove it. After the bearing housing is removed
the air distributor assembly, the sealing and distance rings can be removed from the swivel chamber by us-
ing the swivel house tool (3) and pulling them out.
1
2
3
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
33 / 59
Be sure to store all removed parts in a safe place.
6. Disassembly instructions:
The connection housing can also be further dismantled, by unscrewing the four screws (1), if o-rings (2)
needs to be replaced. In case the sensors, pressure (3) and temperature (4) are malfunctioning they can
also be removed.
If the pressure sensor is removed it needs to be handled with utmost care since even the smallest force to
the pressure plate might cause the sensor to malfunction.
2
2
3
4
1
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 !
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
34 / 59
6. Disassembly instructions:
To access the pistons and material valve needles the cylinder
cover need to be removed. Alternately unscrew the three (1)
screws holding the cover (2) to the cylinder block and remove
it. With the cylinder cover removed the springs (3) can also be
removed.
When the cylinder cover and springs are removed, the needle
pistons (4) can be removed. First loosen the two set screws (5)
on each piston. To facilitate this, the pistons can be pulled up a
few millimeters. With the set screws loosened, the
pistons can be picked up and taken out of the cylinders.
Push the three needles down (6) and unscrew the three screws
(7) that holds the cylinder block in place and remove it. Re-
move the needle packings (8) from the cylinder housing.
1
2
3
4
5
6
7
8
Be sure to store all removed parts in a safe place.
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
35 / 59
Be sure to store all removed parts in a safe place.
6. Disassembly instructions:
The material valve needles, guide and gasket can now be removed from the central body.
With the needles removed, remove the cylinder packing (1) and
pull out the needle packing spacers (2). Note that there are
two sizes. See parts manual for additional information and spe-
cial tools. Remove the needle packings (3) from the
needle packing spacers.
Pick up the needle packings and needle guides with the special tool (6004 0154 11).
2 1
3
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
36 / 59
Be sure to store all removed parts in a safe place.
6. Disassembly instructions:
For applicators with needle sensors or heat rods and PT100
sensor start with disconnecting the needle sensors
connectors (1) from the connectors on the slip ring.
Alternately unscrew the three screws (2) and remove the
cylinder cover (3) and the springs (4).
When the cylinder cover and springs are removed, the needle
pistons (5) can be removed. First loosen the two set screws (6)
on each piston. To facilitate this, the pistons can be pulled up a
few millimeters. With the set screws loosened, the pistons can
be picked up and taken out of the cylinders.
Push the three needles down (7) and unscrew the three screws
(8) that holds the cylinder block in place and remove it.
Remove the needle packings (9) from the cylinder housing.
1
2
3
4
6
5
7
8
9
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
37 / 59
Be sure to store all removed parts in a safe place.
6. Disassembly instructions:
The material valve needles, guide and gasket can now be removed from the central body.
Disconnect the heat rods (1) and PT100 sensor (2) from the
slip ring disk and pull them out of the central body. When
doing this the cylinder packing will most likely come with, pull it
off the rods (3).
Pull out the needle packing spacers (4). Note that there are
two sizes. See parts manual for additional information and
special tools. Remove the needle packings (5) from the needle
packing spacers.
Pick up the needle packings and needle guides in the central
body with the special tool (6004 0154 11), see page 35.
1
3
3
4
5
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
38 / 59
Be sure to store all removed parts in a safe place.
6. Disassembly instructions:
The slip ring disc can be removed by unscrewing the three screws (1) and then sliding it of the central
body.
Make sure to thoroughly clean all parts that will be fitted again. Inspect the cleaned parts for damage and
excessive wear and replace if so necessary.
Discard parts not needed for re-assembly.
Refer to spare parts manual for additional information and spare parts numbers.
1
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
39 / 59
Be sure to store all removed parts in a safe place.
6.1 Optional equipment disassembly instructions:
For an applicator with a fourth valve and air swivel, first remove the hoses (1) that leads the air to the
nozzle. Loosen the screws (2) and slide the swivel lock ring (3) of the central body.
When the lock ring is removed the air swivel house (4) and the air house sleeve (5) can be removed by
sliding them (6) of the central body.
The o-ring support plate (7) can also be removed by unscrewing the two screws. The separation of central
body and swivel is then handled as described on page 30.
1
2
3
5
6
7
4
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
40 / 59
7. Assembly instructions:
Mount the needle packings (1) into the special tool 6004
0154 10 (2), make sure the needle packing faces the right
direction (3).
Insert the tool, with the needle packing mounted, into the
central body and use the special tool 6004 0154 11 to press
the needle packing into place (4). After the needle packings
are mounted insert and push down the needle guides.
Now the packings spacers (5) must be inserted. Please
observe that the end with the smaller dimension (6) must
face the nozzle head, also note the different sizes.
1 2
4
5
6
3
<
<
Before assembly, make sure all spare parts
are available (new in unopened package if so
delivered), other parts thoroughly cleaned.
NOTE
Ensure a proper work bench with a vice with
soft jaws. Do not fasten the central body
on the sleeve. Suitable lubricant and thread
locking compound should also be available.
CAUTION !
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
41 / 59
7. Assembly instructions:
Mount the cylinder packing (1) and insert the needle
packings into the packing spacers. Note the different hole
sizes of the cylinder packing. The smaller size holes (2) are for
the air channels and the bigger (3) are for the cylinder block
screws. When mounting the needle packings on the top of the
needle spacers the special mounting tool must be used in the
same manner as when mounting the needle packings in the
central body.
Mount the cylinder block (5) on the central body and fasten it
with the three screws (6). Note that the needle packings (7)
must be mounted before the cylinder block can be attached to
the central body. When mounting the needle packings the
special mounting tool must be used in the same manner as
when mounting the needle packings in the central body.
Apply light lubrication to the inside walls of the cylinders (8).
Make sure to dry off any lubricant that gets to the bottom (9)
of the cylinders.
1
2 3
7
5
6
8
9
4
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
42 / 59
7. Assembly instructions:
Mount the gasket (1) and insert the needle guide (2) and needles (3), lightly lubricate (4) the top of the
needles. Inserting the needles is easiest done with the central body in a horizontal position.
With the cylinder block and needles in position the pistons, lightly lubricated (5) on its sides, can be
inserted in the cylinders and pushed firmly to the bottom position. The needle is then pushed against the
piston (6), with some pressure against the piston (7), to make sure that the needle bottoms out in the
piston.
The needle is then fixed with two set screws (8) on each
piston. Alternately tighten the screws. When tightening the
screws, a small drop of soft thread sealant (Loctite) should be
used on the threads of the screws so that the screws stay put
and to avoid air leakage through the threads. Wipe off any
excess sealant after the screw has been fastened.
1
2
3
4
5
6
7
8
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
43 / 59
7. Assembly instructions:
When the pistons are fixed, the springs (1) are inserted into the pistons and the cylinder cover (2) is
fastened with the three screws (3). Alternate between the screws when fastening the cover.
The central body is assembled and can be, if service has been done on the swivel and connection housing,
inserted into the swivel housing.
If your applicator have either needle sensors and/or heat rods and PT100 sensor the assembly is described
below. Avoid touching the slip ring disc when assembly the central body. Dirt on the slip ring can lead to
sensors and heating rods malfunctioning.
Follow the normal instructions for central body assembly up
until the cylinder packing and needle packings are inserted into
the needle spacers. See page 40.
The heat rods (4) and PT100 sensor (5) are then inserted into
the central body and connected to the connectors in the slip
ring disc.
1 3
2
4
5
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
44 / 59
7. Assembly instructions:
Follow the normal assembly instructions (see page 39) to
mount the cylinder block and inserting the needles. Note the
cutouts (1) in the cylinder block for the heat rod and PT-100
sensor cables. Important! When using sensors and heat rods
in the central body, use a torque tool to fasten the screws
holding the cylinder block. Recommended torque is 3 Nm.
When the pistons are fixed, the springs (2) are inserted
into the pistons and the cylinder cover (3) is fastened
with the three screws (4). Alternate between the screws
when fastening the cover.
Connect the needle sensors (5) to the connectors on the
slip ring disc.
The central body is assembled and can be, if service has
been done on the swivel and connection housing,
inserted into the swivel housing.
If the sensor cables were disconnected note the order of
the cables in the connector below.
1
2 4
3
1
1 2 3
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
45 / 59
Angle the seal ring to avoid the sharp edge. Push the seal ring into place using the swivel
house tool.
If 3 seal rings are used the second one is
placed between the material rings.
7. Assembly instructions:
The swivel chamber is described on page 8. When assembling the swivel chamber it is important that the
various parts are assembled in the correct order.
Follow instructions below on how to mount seals in the swivel housing in a safe way and avoid o-ring
damage. Always use spare parts from your dealer. Item article numbers can be found in the spare parts list
for your model. For easy installation lightly lubricate o-rings and seals!
Sharp edge
Sharp edge
Push the seal ring into place using the swivel
house tool. (only if 3 seal rings are used)
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
46 / 59
Push down the seal ring using the swivel
house tool.
Lightly lubricate the inside of the swivel
chamber. Use the O-ring mounting protector
to cover the sharp edges. Lightly lubricate
the side facing the air ring.
Sharp edges
Push down the air ring with your thumbs.
Lightly lubricate the O-rings for easier
mounting.
Pull out the plastic strip.
7. Assembly instructions:
Angle the seal ring to avoid the sharp edge.
Sharp edge
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
47 / 59
7. Assembly instructions:
When all the parts are mounted in the swivel chamber the bearing housing (1) can be fastened with four
screws (2). Do not forget to mount the two bearings (3) on both sides of the swivel.
When mounting the bearing housing note the four pins (4) and the corresponding holes in the air
distributor ring (5). They need to be aligned when the bearing housing is fastened and stops the air
distributor ring from rotating.
1
2
3
3
5
4
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
48 / 59
7. Assembly instructions:
If a major service was done the manifold packing (1), the manifold (2) and the three solenoid valves (3)
needs to be mounted on the swivel house.
For a major service the connection housing also needs to be put back together and mounted to the swivel
housing. Start with attaching the upper connection piece to the lower, do not forget the o-rings (4). Mount
the connection housing to a already serviced swivel housing. When mounting the connection housing on
the swivel housing it is important to check that the packings for material are in their correct positions (5).
4
5
2
3
1
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
49 / 59
7. Assembly instructions:
When the connection housing is mounted to the swivel, if the cables for the valves and sensors (if they are
available) were disconnected reconnect them to the connector. Attach and screw the cables (1) for the
solenoid valves to the solenoid vales. Then fasten the three covers (2) for the connection house and the
cover for the solenoid valves (3).
If the applicator have needle sensors and/or heat rods and PT-100 sensor it has a slip ring disc (4) with
brushes. Important! The brushes on this disc are very fragile and it should only be mounted just before
the central body is ready to be assembled with the swivel housing. The slip ring disc with brushes is
fastened with three small screws (5).
3
2 2
1
4
5
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
50 / 59
7. Assembly instructions:
Fasten (1) the connection housing in a vice with soft jaws and lightly lubricate the seals inside the swivel
chamber and the sleeve on the central body (2). Slide the central body into the swivel chamber and apply
moderate force to push (3) it all the way down, twisting (4) the central body while pushing helps.
Slide the swivel lock onto the central body and while applying moderate force (5) fasten the screws (6).
Important! The screws in the swivel lock should be firmly fastened but not to tight, note the play between
the two halves (7). Mount the seal ring (8).
4 2
3
1
5
7
8
6
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
51 / 59
7. Assembly instructions:
Align the nozzle head holes (1) with the guide pins (2) on the central body, make sure that the gasket (3) is
in place. Fasten the nozzle head with the three screws (4). Insert the nozzle packing (5) then mount the
nozzles in the slots (6) in the nozzle cap and use the screw (7) to attach the nozzle cap to the nozzle head.
For an applicator with an adapter and rectangular nozzle head start with aligning the nozzle head holes (8)
with the guide pins (9) on the central body. Make sure that the gasket (10) is in its place then mount and
fasten the adapter (11) with three screws, the two screws (12) for fastening the adapter and one of the
screws (13) for fastening the rectangular nozzle head. The one screw (13) should be used in the hole (14)
with the bushing, and is unscrewed when the adapter is fastened. Insert the adapter packings (15) then
align the bushing (14) and pin (16) with the corresponding holes (17) in the nozzle head and fasten the
nozzle head with the two screws (13 and 18). Insert the three nozzle packings (19) in the nozzle head. In-
sert the nozzles in the three nozzle plates (20) and fasten them on the nozzle head with the two screws
(21) for each plate. Note the different sizes of the bushings (22) and the corresponding holes (23) in the
nozzle plates.
1 2
3 4 5 6
7
6
8
9
10
12
11
13
19
18
14
15
16
17
20
23
22
19
21
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
52 / 59
7.1 Optional equipment assembly instructions:
If the applicator has a 4th valve and a air swivel start with
attaching the 4th valve (1) to the manifold and the electric
cable (2) to the valve. Insert the o-rings (3) and fasten the
o-ring support plate (4) with the two screws (5).
Insert two 25 mm, 4 mm Ø hoses (6) into the support plate
(4), make sure to push them all the way down in the
manifold. Lightly lubricate the inside of the air swivel sleeve
(7), very lightly lubricating the central body is also
recommended. Note that it does not matter if the o-rings (8)
inside the sleeve take damage when mounting it.
Make sure that the air swivel sleeve is pressed all the way
up against the swivel housing (9). Align the sleeve, the pin
hole (10), with the pin hole (11) in the central body or with
the position of the couplings (12) on the nozzle head.
1
2
3
5
4
5
7
8
9
10
11 12
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
53 / 59
7.1 Optional equipment assembly instructions:
Lightly lubricate the seals (1). Align the couplings with the
hoses (2) and mount the air swivel house (3) onto the
sleeve. Note the amount of seals in the spare part list for
your applicator and the orientation of the v-seal lip (4).
Mount the o-rings (5) in the sleeve.
Insert the O-rings (6) and two 10mm, 4 mm Ø hoses (7)
into the lock ring and mount it against the sleeve (8). The
screws (9) in the swivel lock should be firmly fastened but
not to tight, note the small play between the two halves
(10).
Mount the nozzle adaptor or the air nozzle to the central
body and attach the hoses (11). Note the pin (12) and the
o-ring (13) for the air nozzle.
3
4 4
2
5
6
7
10
1 1
13
12 11
11
9
8
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
54 / 59
7.2 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 open-
ing 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 a last check on all fasteners and then follow the installation instructions (Chapter 4) to mount the
applicator on the robot.
If the applicator has slipring discs, control that the distance between slip ring disc and the electric slip ring
brushes are approximately 2,1 - 2,3 mm. If the distance is not within this interval, contact the
manufacturers.
2,1 mm—2,3 mm
Electric slip ring brushes
Slip ring disc
If the applicator is tested off-line with mate-
rial pressure applied it’s very important to
take appropriate safety measures to prevent
personal injury!
WARNING !
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
55 / 59
8. Technical specifications:
Torque requirement Nm
M3 1.35
M4 3.3
M5 6.5
M6 11.1
M8 26.6
415 Stainless Steel
(operational)
415 (operational)
Weight Approx. 6.2 kg Approx. 3,7 kg
Length 471 mm 493 mm
Swivel height 202 mm 202 mm
Mounting arrangement Robot mounting flange Robot mounting flange
Max working pressure 250 bar 250 bar
Max working temperature 80° C 80° C
Material inlet Male 1/2 BSP connector Male 3/8 BSP connector
Material return Male 3/8 BSP connector Male 3/8 BSP connector
Air ports 8 mm 8 mm
Minimum air pressure requirement 5,5 bar 5,5 bar
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
56 / 59
9. Dimensions:
Normal connection housing
Round nozzle head
Low connection housing
Square nozzle head
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
57 / 59
9. Dimensions:
Low connection housing
4th valve with air swivel
Nozzle head adaptor for air
Dual material connection housing, with circulation
Round nozzle head
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025)
58 / 59
10. 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 swivel chamber 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 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 the preventive
maintenance.
The figures below can thus only be used as a 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 E415 applicator according to chapter 5-6.
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
EN
www.Binks.com Manual 9836 4173 01-R2 (07/2025) 59 / 59
