- IntelliFlow Dispense Pump 77-3167 [ English ]
77-3167
IntelliFlow Dispense Pump
®
www.binks.com77-3167 R1 (05/2025)
ENADDITIONAL RESOURCES
For additional information or copies of your service manual, please visit us online at:
binks.com/en/library
Or use this QR code with your mobile device:
RF2+
Obey local or municipal regulations for product recycling and disposal.
RF2
RM2
https://carlisleft.com/en/product/is40-proportioner/
www.binks.com 77-3167 R1 (05/2025)
EN INTRODUCTION
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ABOUT THIS MANUAL
ITS PURPOSE
The purpose of this manual is to help you get the most
value from your Binks IntelliFlow system. It can help you
to determine how to install, operate, maintain, and repair
your equipment. It provides information and procedures
for routine maintenance and servicing and offers
diagnostic and repair procedures to follow when trouble
occurs.
ITS CONTENTS
This manual is divided into Chapters, each of which is
divided into consecutively numbered Sections.
Chapters will contain text, images, tables, or a
combination of them.
Pages with images will have paragraphs and sentences
with callout numbers that refer to their respective images,
steps, and parts.
Procedures, once described in the text, are not normally
repeated. When it is necessary to refer to another
Chapter or Section, the reference will be given as Chapter
and Section number. Cross references given without
the use of the word Chapter apply to Sections or
paragraphs in the current Chapter.
Chapter 02. Table of Contents.
Chapter 03. Safety - Safety, hazard, and warning rules.
Chapter 04. Introduction - Basic introduction of the
dispense pump.
Chapter 05. Servicing - Instructions on the servicing of the
dispense pump.
Chapter 06. Maintenance - Dispense pump maintenance
instructions.
Chapter 07. Manual Change Summary - The revisions
and changes made to this manual.
Chapter 08. Warranty - Your equipment’s warranty.
WHO SHOULD USE THIS GUIDE
This guide is intended for users with different levels of
knowledge and experience with this system:
Installers: The person(s) who will locate and install this
equipment.
Users: The person(s) who will learn how to operate this
equipment.
Servicers: The person(s) who will service and maintain
this equipment.
This guide assumes all persons who will install, use,
operate, and service this equipment have some
knowledge of the product and its operating system.
MANUAL DISCLAIMER
All current and applicable certifications shown in this
manual confirm Binks' adherence to the strict standards
met to obtain the required regulatory compliances.
This manual was prepared with the most accurate
information current at the time of publishing. Binks does
not accept responsibility for errors in, or omissions from,
the information contained herein.
Please get in touch with your distributor or Binks
Customer Service for additional service information and
assistance.
www.binks.com77-3167 R1 (05/2025)
ENINTRODUCTION
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DISPENSE PUMP RELATED MANUALS & PUBLICATIONS
Part Number Description
77-3153-1 RM2 Installation Manual
77-3153-3 RM2 Service Manual
77-3161-1 RE1 Installation Manual
77-3161-3 RE1 Service Manual
77-3165-1 RF2+ Installation Manual
77-3165-3 RF2+ Service Guide
www.binks.com 77-3167 R1 (05/2025)
EN 02. TABLE OF CONTENTS
iii / iv
02. CONTENTS
03 SAFETY 3
03.1 SAFETY PRECAUTIONS..................................................................................................................................3
03.2 ADDITIONAL SAFETY INFORMATION..........................................................................................................10
04. INTRODUCTION 11
04.1 DISPENSE PUMP SPECIFICATIONS............................................................................................................12
04.2 DISPENSE PUMP PARTS LIST......................................................................................................................13
05. DISPENSE PUMP SERVICING 15
05.1 GENERAL TIPS................................................................................................................................................15
05.2 GENERAL TROUBLESHOOTING..................................................................................................................15
05.3 PREVENTATIVE MAINTENANCE..................................................................................................................15
05.3.1 DAILY MAINTENANCE.........................................................................................................................15
05.3.2 MONTHLY MAINTENANCE..................................................................................................................15
05.3.3 AS NEEDED MAINTENANCE..............................................................................................................15
06. MAINTENANCE 17
06.1 PRELIMINARY PROCEDURES......................................................................................................................17
06.2 DISPENSE PUMP REMOVAL.........................................................................................................................17
06.3 DISPENSE PUMP DISASSEMBLY.................................................................................................................18
06.4 INSPECTION....................................................................................................................................................22
06.5 ASSEMBLY........................................................................................................................................................24
06.6 DISPENSE PUMP INSTALLATION.................................................................................................................29
07. MANUAL REVISIONS 31
08. WARRANTY 33
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EN02. TABLE OF CONTENTS
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EN 03. SAFETY
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03 SAFETY
03.1 SAFETY PRECAUTIONS
Before the operation, maintenance, or servicing of this
Binks system; fully read and understand all technical
and safety literature for your product. This manual
contains information that is important for you to know and
understand.
This information relates to USER SAFETY and the
PREVENTION OF EQUIPMENT PROBLEMS.
To help you understand this information, we use
recognizable ANSI Z535 and ISO warning boxes and
symbols throughout this manual. Please obey these
safety sections.
Careful study and continued use of this manual will
provide a better understanding of the equipment functions
and procedures.
This understanding will result in improved operation,
efficiency, and longer, trouble-free service with faster and
easier troubleshooting. If you need the necessary safety
literature for your specific system, contact your local Binks
representative or Binks directly.
WARNING
WARNING!: Indicates a hazardous situation that, if not
avoided, could result in death or severe injury.
CAUTION
Caution!: Indicates a hazardous situation that, if not
avoided, could result in minor or moderate injury, or
equipment damage.
NOTICE
Notice: Indicates information considered important but
not hazard related.
DANGER
DANGER!: Indicates a hazardous situation that, if not
avoided, will result in death or severe injury.
SAFETY
Safety: Indicates a type of safety instruction, or a
separate panel on a safety placard, where specific
safety-related instructions or procedures are described.
WARNING
The hazards shown on the pages that follow can occur
during the normal use of this Binks equipment, but
not all listed hazards will be applicable to your product
model or equipment.
Repairs may only be performed by personnel
authorized by Binks.
WARNING
The user MUST read and be familiar with the Safety
Section in this manual and the safety literature therein
identified.
Only trained personnel can operate this equipment.
All personnel who operate, clean, or maintain this
equipment MUST fully read and understand this
manual! To operate and service the equipment, follow all
WARNINGS and safety requirements.
The user must be aware of and adhere to ALL local
building and fire codes and ordinances, as well as NFPA
33 AND EN 16985 SAFETY STANDARDS, LATEST
EDITION, or applicable country safety standards, before
the installation, operation, or servicing of this equipment.
NOTICE
This manual lists standard specifications and service
procedures. Differences can occur between this
literature and your equipment.
Differences in local or municipal codes, manufacturer
or plant requirements, material delivery requirements,
and more can make variations unpreventable. To
find these differences, compare this manual to your
system installation drawings and other applicable Binks
equipment manuals.
EN03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Spray Areas Fire Hazards
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire
hazard.
If the safety interlocks are
disabled during operation,
protection against accidental
arcing is shut off and can cause
a fire or explosion.
Frequent Power Supply or
Controller shutdown identifies a
problem in the system. For this
occurrence, a correction will be
necessary
Fire extinguishing equipment must be present in the
spray area. Periodically run a test to make sure the
equipment stays usable.
Keep spray areas clean to prevent the build-up of
combustible residues.
Do not smoke in the spray area.
The high voltage supplied to the atomizer must be
turned off before the equipment is cleaned, flushed
or maintained.
Spray booth ventilation must be kept at the rates as
set by NFPA-33, OSHA, country, local, and municipal
codes.
If flammable or combustible solvents are used to
clean the equipment, ventilate the area.
Prevent electrostatic arcing. Maintain spark-safe
work distance between the parts that get coated and
the applicator. A span of one inch for every 10KV of
the output voltage is necessary.
Do an equipment test only in areas free of
combustible material. The test may necessitate the
high voltage to be on, but only as instructed.
Non-factory replacement parts or unauthorized
equipment modifications can cause a fire or injury.
The key switch bypass is used only during setup
operation.
Do no production work with disabled safety
interlocks.
Set up and operate the paint procedure and
equipment under NFPA-33, NEC, OSHA, local,
municipal, country, and European Health and Safety
Norms.
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Spray Areas
General Use and
Maintenance
Explosion Hazard
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire or
explosion hazard.
If the safety interlocks are
disabled during operation,
protection against accidental
arcing is shut off and can cause
a fire or explosion.
Frequent Power Supply or
Controller shutdown identifies a
problem in the system. For this
occurrence, a correction will be
necessary.
Improper or unsatisfactory
operation and maintenance
procedures will cause a fire
hazard.
Personnel must be correctly
trained in the operation and
maintenance of this equipment.
Prevent electrostatic arcing. Maintain spark-safe
work distance between the parts that get coated and
the applicator. A span of one inch for every 10KV of
output voltage is necessary.
Unless specifically approved for use in hazardous
locations, put all electrical equipment outside of
Class I or II, Division 1 or 2 hazardous areas in
accordance with NFPA-33, or outside of Zone 2 or
Zone 22 in accordance with EN standards.
If equipped, set the current overload sensitivity as
described in the related section of the equipment
manual. If incorrectly set, the current overload
sensitivity for protection against accidental arcing is
turned off and can cause a fire or explosion.
Frequent power supply shutdown indicates a
problem in the system, which requires correction.
Always turn off the control panel power before the
system is flushed, cleaned, or servicing the spray
system equipment. Make sure no objects are within
the spark-safe work distance before the high voltage
is turned on.
The control panel must interlock with the ventilation
system and conveyor in accordance with NFPA-33,
EN 50176.
Fire extinguishing equipment must be present in the
spray area. Periodically run a test to make sure the
equipment stays usable. Do an equipment test only
in areas free of combustible material.
Train all personnel in accordance with the
requirements of NFPA-33, EN 60079-0.
Before equipment operation, personnel must read
and understand these instructions and safety
precautions.
Obey appropriate local, municipal, state, and
national codes governing ventilation, fire protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms, and your
insurance company requirements.
EN03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Spray Area High
Voltage Equipment
Electrical Discharge
This equipment contains a
high-voltage device that can
cause an electrostatic induction
on ungrounded objects. This
electrical charge is capable of
igniting coating materials.
Insufficient ground will cause a
spark hazard. A spark can ignite
many coating materials and
cause a fire or explosion.
Operators in the spray area and the parts to be
sprayed must be sufficiently grounded.
All conductive objects inside the spray area must be
grounded.
Hold the parts that get sprayed on conveyors or
hangers that are correctly grounded. The resistance
between the parts and the earth-ground must not be
more than 1 MΩ. Refer to: NFPA-33.
Before the equipment is operated, ground all
operators. They cannot wear rubber-soled insulated
shoes. Wear ground straps on wrists or legs for
sufficient ground contact.
Operators must not wear or carry ungrounded metal
objects.
When used, operators must make complete contact
with the applicator handle and electrostatic gun. Use
conductive gloves or gloves with the palm section cut
out.
Operators must wear grounded footwear.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES FOR GUIDANCE TO
CORRECTLY GROUND THE OPERATOR.
Except for objects needed for the high-voltage
process, all electrically conductive objects in the
spray area are to be grounded. Supply a grounded
conductive floor in the spray area.
Always turn off the applicator voltage before the
system is flushed, cleaned, or when servicing the
spray system equipment.
Unless specifically approved for use in hazardous
locations, put all electrical equipment outside of
Class I or II, Division 1 or 2 hazardous areas in
accordance with NFPA-33, or outside of Zone 2 or
Zone 22 in accordance with EN standards.
Do not install an applicator into a fluid system if the
solvent supply is ungrounded.
Do not touch an energized applicator electrode.
EN 03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Spray Areas
Spray Area and
Equipment Use
Toxic Fluid or Fumes
Toxic fluids or fumes can cause
severe injury or death if splashed
in the eyes or on the skin, or if
inhaled or swallowed.
High-pressure fluid sprayed
from the gun, hose fittings, or
ruptured/damaged components
can pierce the skin.
While this injury can appear as
cut skin, this is a severe injury
that can result in the amputation
of the affected area.
Read the Safety Data Sheet (SDS) for instructions
to know and understand how to handle the specific
hazards of the fluids used, and the effects of long-
term exposure.
During the spray, clean, or servicing of equipment,
or when in the work area, keep the work area fully
ventilated.
Always wear personal protective equipment (PPE)
when in the work area or during equipment operation.
Refer to the Personal Protective Equipment warnings
in this manual.
Store hazardous fluid in approved containers and
refer to local, municipal, state, and national codes
governing the disposal of hazardous fluids.
Do not point or operate the spray gun at the body
part of a person.
Do not put your hand or fingers over the gun fluid
nozzle or fittings in the hose or Proportioner.
Do not try to stop or deflect leaks with your hand,
glove, body, or shop rag.
Do not blowback fluid, as the equipment is not an
air spray system.
Relieve pressure in the supply hoses, Proportioner,
and QuickHeat™ hose before the equipment is
inspected, cleaned, or serviced.
Use the lowest possible pressure to recirculate,
purge, or troubleshoot the equipment.
Examine the hoses, couplings, and fittings every day.
Service or immediately replace parts that leak, are
worn, or are damaged. Replace high-pressure hose
sections. They cannot be recoupled or serviced.
EN03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Equipment
and Fluids
Pressurized
Aluminum Parts
Skin and Clothing Burns
Equipment surfaces and fluids
can become very hot during
operation.
The use of certain solvents and
chemicals can cause equipment
damage and severe personal
injury.
Do not touch hot fluid or equipment during operation.
Do not let clothing touch the equipment during
operation or immediately after the equipment is
stopped.
Let the equipment fully cool before the examination
or servicing of the component.
Do not use 1,1,1-trichloroethane, methylene
chloride or other halogenated hydrocarbon solvents
or fluids that contain such solvents.
These solvents can cause a severe chemical
reaction and equipment rupture that results in
equipment and property damage, serious bodily
injury, or death.
EN 03. SAFETY
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AREAS
Indicate possible
hazard occurrences.
HAZARDS
Indicate possible hazards.
SAFEGUARDS
Prevention of possible hazards.
Spray Areas Do Not Touch
The effect of paint flow rates
and formulations on the quality
of atomization can cause the
turbines to rotate at high speeds.
Do not use a rag or gloved hand against the bell
edge to stop or slow down a bell during rotation.
Do not try to clean the bell edge during rotation.
EN03. SAFETY
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If the operation of this equipment, sensors, switches, or other ancillary equipment occurs in the presence of flammable
gases and vapors, connect this equipment through intrinsic-safe or Zener barriers. Classify them as a ‘simple apparatus’
or approve them for use in these areas.
03.2 ADDITIONAL SAFETY INFORMATION
The IntelliFlow has an emergency stop (E-Stop) pushbutton on the main operator panel. During an emergency, all
operations for the IntelliFlow will halt when the E-Stop is engaged. The operator must disengage the E-Stop and reset
the system to recover from this state.
Observe all local or municipal safety measures and wear approved protective equipment when servicing this equipment.
Clean all spilled chemicals and materials and do all work in a clean and organized environment to prevent personal
injury and equipment damage.
NOTICE
During the initial commission of the equipment and at periodic times throughout equipment life, visually examine all
fluid fittings for leaks.
Periodically, it is necessary to visually examine all pieces of this equipment for signs of noticeable degradation due to
chemicals or other conditions in the equipment’s environment.
CAUTION
Only operate the equipment after you have read this section.
DANGER
To prevent injury or electrocution while the system is under power, do not contact, disconnect, or manipulate electrical
connections or devices. The main disconnect on the right side of the controller can be locked out. Follow the proper
Lockout–Tagout (LOTO) procedures for internal controller electrical work.
Only qualified electrical personnel can perform the work if diagnosis and troubleshooting are not possible during
working conditions.
WARNING
To prevent possible chemical spillage when personnel are not on site, air and fluid supplies for the equipment must be
disabled when the equipment idles for an extended period, such as an end-of-day shutdown.
SAFETY
Obey local or municipal regulations that require installed fire suppression for equipment operation.
EN 04. INTRODUCTION
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04. INTRODUCTION
The Intelliflow™ dispense pump uses an electronically
controlled stepper motor equipped with an integral linear
actuator to control material flow. The pump is available in
both 300 cc and 600 cc sizes, which operate in the same
way.
Inlet and outlet valves on each end of the pump control
material flow. Open valves are indicated by small
protrusions that appear white on the side of the dispense
pump.
As the pump piston moves down, the top outlet valve
is closed, and the top inlet is open. This action draws
material into the top of the cylinder above the piston.
When the piston reaches the bottom of its stroke, the
valve settings and piston direction reverse, dispensing the
material in the top of the cylinder and filling the bottom.
A balancing mechanism programmed into the system
controller minimizes pressure fluctuations during piston
reversals. This logic assumes that the inlet material
pressure exceeds the dispenser output pressure. When
the dispenser reaches the limit of the potentiometer,
the inlet valve closes, and the outlet valve opens. This
action continues dispensing material on the output side
while filling material on the inlet side. When the inlet side
pressure is drawn down to match the output pressure, the
direction reverses. The appropriate valves open, and the
filling side dispenses.
The dispense pump is fitted with a linear potentiometer
with a wiper, both located within the machine control
enclosure. The movement of the motor's screw slides
the wiper on the potentiometer and communicates the
position of the pump piston.
The dispense pump has two oil reservoirs, which hold a
small amount of oil to lubricate the pump shaft seal. The
oil level should be maintained in the center of the clear
tubing.
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04.1 DISPENSE PUMP SPECIFICATIONS
Pressure Rating
Maximum Fluid Pressure 300 PSI
Ports Thread Sizes
Top Elbows #10-32
Inlet and Outlet ¼ NPT
Pneumatic Elbows 1/8 NPT
Pressure Sensor 7/16-20 UNF-2B (SAE-4)
Socket Head Cap Screws ¼-20 UNC-2B
Injector Thread 1-12 UNF-2B
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04.2 DISPENSE PUMP PARTS LIST
1
2
3
4
5
6
7
8
9
10
11
12 13
14
15 16
17
18
19
20
21
23
14
17 16
15
22 24
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Dispense Pump Spare Parts List
Item Part Number Description Qty Notes
1 240-3020 Pump Rod Adapter 1
2 20-6953 Hex (Jam) Nut 1
3 237-729 Retaining Ring (Snap Ring) 1
4 237-727 Flat Washer 1
5 240-3221 Seal Holder 1
5 240-3222 Rod Guide (within Seal Holder) 1
6 240-3211 Rod Seal 2
7 79001-09 O-Ring, 2-015, solvent proof 1
8 FEP-0403 Teflon Paint Hose, 1/4 OD x 3/16 ID, 210 psi wp 2
9 240-3102 1/4 ODT Cap 2
10 240-5133 Top Block 1
11 20-4844 Dowel Pin, 3/16 DIA x ½ LONG, SS 2
12 77367-00 Microvalve (MCV) Seat Assembly 4
13 78949-00 Microvalve (MCV) Assembly 4
14 79001-05 O-Ring, 2-010, KALREZ 4
15 79001-21 O-Ring, 2-020, Perfluoroelastomer 2
16 240-3022 Cylinder Adapter 2 **
17 79001-18 O-Ring, 2-027, Perfluoroelastomer 2 **
18 240-5135 Fluid Tube 2
19
240-3212-300
240-3212-600
300 cc Piston Seal
600 cc Piston Seal
2
20
240-3018-300
240-3018-600
300 cc Cylinder
600 cc Cylinder
2
21
240-3224-300
240-3224-600
300 cc Rod and Piston Assembly
600 cc Rod and Piston Assembly
1
22 240-5132 Bottom Block 1
23 7959-176C Socket Head Cap Screw, ¼-20 x 5.5 LG, 18-8 4 14.0 N•m (10 lb-ft)
24 35-5735 Fitting, 90 swivel 5/32t x 1/8 NPTM Coated Thread 4
— 0114-016099 Pump Packing Lube, 250 mL 1
**600 cc dispense pump only
EN 05. SERVICING
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05. DISPENSE PUMP SERVICING
05.1 GENERAL TIPS
1. Work from a clean, dry bench.
2. Use only lint-free wipes or cloths for cleaning.
3. Refer to the model number of the dispense pump
when ordering replacement parts.
05.2 GENERAL TROUBLESHOOTING
Follow these steps to identify potential problems with the
dispense pump. Avoid unnecessary disassembly.
1. Check that the system is not in the alarm state. An
alarm may be causing the pump to stop.
2. Verify there are no leaks where fluid enters or leaves
the pump.
3. Examine oil reserves. Look for overflowing liquid or
material in the reservoir.
4. Check for air in all fluid lines. There must be no
bubbles anywhere.
5. Visually inspect the threaded actuator rod, looking
for wear or damage. Check the rod for adequate
lubrication.
6. Verify that the ball plunger correctly contacts the
linear potentiometer. Observe the center valve
change on the dispense pump limits screen during
the jog-up or job-down movement.
7. Trigger the spray gun into a grounded metal waste
container. Confirm valve operation and look for a
constant stream of material exiting the gun.
8. Examine the stepper motor. Verify smooth operation
when the pump runs.
9. Verify that Signal 1A and Signal 1B (the top two LEDs
on the leftmost card of the I/O block) light up and
flash when the material travels through the unit.
10. Verify that the threaded actuator is securely
connected to the pump piston at the coupling.
05.3 PREVENTATIVE MAINTENANCE
05.3.1 DAILY MAINTENANCE
Examine the dispense pump for air and fluid leaks.
05.3.2 MONTHLY MAINTENANCE
1. Ensure the dispense pump oil reservoirs have no
hardener or contamination. This may indicate a leak
in the shaft seal.
2. Check pump oil gauges. A low level may indicate a
leak in the shaft seal.
2.1. If the levels have dropped below the lower edge
of the reservoirs, oil must be added to the pump.
2.2. Before adding oil, check for leaks.
2.3. If there are leaks, contact Binks for assistance.
2.4. Refill the reservoirs with DeVilbiss SSL-10 gun
oil.
3. Ensure sufficient lubrication in the dispense pump.
05.3.3 AS NEEDED MAINTENANCE
1. Verify dispense pump runs smoothly.
2. Reset limits for the dispense pump using the pump
setup screen. Refer to the manual for your RE1,
RM2, RF2, or RF2+ machine for these instructions.
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EN 06. MAINTENANCE
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06. MAINTENANCE
This chapter contains procedures for disassembly,
inspection, and assembly of the dispense pump.
The following tools and supplies are required to
perform maintenance on the dispense pump:
• 5/16 Allen wrench
• 3/16 Allen wrench
• 4 mm Allen wrench
• 11 mm wrench
• 13 mm wrench
• 21 mm wrench
• Adjustable wrench
• Mallet
• Snap ring pliers
• Plastic pry tool
• Seal puller or hook for removing O-rings
• Screwdriver
• Q-tips
• Multi-purpose synthetic grease, such as
Mesamoll®
• DeVilbiss SSL-10 gun oil
06.1 PRELIMINARY PROCEDURES
Before removing the dispense pump for service or
repair, perform the following procedure:
1. Flush the dispense pump. Do not refill with
solvent.
2. If equipped, close the shut-off valves on the
dispense pump.
3. Turn off pneumatic air (if using).
4. Turn off power.
5. Place a container nearby for collecting oil or
other liquid that may come out of the pump
during disassembly.
6. Unscrew the inlet and outlet hose connections
from the dispense pump.
7. Remove the pressure sensors from the dispense
pump.
06.2 DISPENSE PUMP REMOVAL
1. Using a 4 mm Allen wrench, unscrew the four bolts
holding the coupling.
2. Remove the bolts.
3. Pry open the two halves of the coupling using a
screwdriver.
4. Remove coupling.
5. Place a 21 mm wrench on the coupler that attaches
the dispense pump to the machine and a 13 mm
wrench on the pump rod adapter.
5.1. Pull the wrenches inward (toward each other)
to loosen the components.
5.2. Once the components are loosened, unscrew
the pump rod adapter.
CAUTION
Turn off power before removing the dispense pump for
service or repair.
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6. Measure the distance between the top of the
pump rod adapter (item 1) and the top of the
housing flange.
6.1. Record the measurement for later use.
This example is approximately 8.4 mm.
6.2. The measurement is the length the pump
rod must be positioned during installation
for the coupling to fit.
06.3 DISPENSE PUMP DISASSEMBLY
1. Drain the fluid from inside the dispense pump.
1.1. Remove oil gauge caps (item 9)
1.2. Tip the pump toward the open oil gauge tubing
(item 8) and pour the oil into a waterproof
waste container.
1.3. Dispense pumps typically contain
approximately 12 oz of oil. However, the oil is
dispersed throughout the pump.
2. Detach the bottom block (item 22) from the top block
(item 10).
2.1. Using a 3/16 Allen wrench, turn one socket
head cap screw (item 23) counterclockwise to
loosen it from the bottom block.
2.2. Loosen the remaining three screws and then
unscrew them completely by hand.
2.3. Remove the bottom block.
NOTICE
Keep a record of the length between the top of the
pump rod adapter and the top of the housing flange for
later use.
NOTICE
Some oil will drip out as components are removed.
EN 06. MAINTENANCE
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3. Pull the fluid tubes (item 18) out of their grooves in
the bottom block.
4. Remove the pump rod adapter (item 1) and hex jam
nut (item 2).
4.1. Secure an 11 mm wrench to the jam nut and a
13 mm wrench to the pump rod adapter.
4.2. Holding the jam nut still, turn the pump rod
adapter counterclockwise to loosen the pieces.
4.3. Unscrew the pump rod adapter.
4.4. Secure the end of the pump rod assembly
visible from the bottom of the cylinder (item 20)
with an adjustable crescent wrench. Carefully
hold the rod assembly in place.
4.5. Using a 11 mm wrench, turn the jam nut
counterclockwise to loosen it.
4.6. Unscrew the jam nut.
5. Remove the piston assembly (item 21) and cylinder
(item 20) from the top block (item 10).
5.1. Remove the cylinder from the top block.
5.2. Carefully but firmly push the piston assembly
from the cylinder.
6. 600 cc dispense pump only: Remove cylinder
adapters (item 16) from the top block (item 10) and
bottom block (item 22).
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6.1. Remove the cylinder adapter from the bottom
of the top block.
6.2. Remove the cylinder adapter from the top of
the bottom block.
7. Remove the flat washer (item 4) and the snap ring
(item 3) from the top block.
7.1. Using the snap ring pliers, pinch the snap ring
to reduce its size.
7.2. Remove the snap ring from the top block.
7.3. Remove the flat washer.
7.4. Remove the rod seal (item 6) beneath the flat
washer.
8. Remove the seal holder assembly from the top block.
8.1. Insert a 5/16 Allen wrench into the bottom of
the top block.
8.2. Carefully push the seal holder assembly from
the block.
8.3. Remove the second rod seal (item 6) from the
seal holder assembly.
CAUTION
Avoid using sharp or pointy tools to remove the seal
holder assembly from the dispense pump. The seal
holder assembly may not function as intended if
damaged.
EN 06. MAINTENANCE
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9. Remove the four MCV assemblies (item 13) and MCV
seat assemblies (item 12) from the ports on the sides
of the top and bottom blocks.
9.1. Insert the MCV tool into the indentations on an
MCV assembly.
9.2. Secure an adjustable wrench to the MCV tool.
9.3. Loosen the MCV assembly by turning the
wrench counterclockwise.
9.4. Remove the assembly from the port.
9.5. Insert the back of a 5/16 Allen wrench in the
MCV port.
9.6. Loosen the seat assembly by turning the
wrench counterclockwise.
9.7. Remove the seat assembly from the port.
9.8. Repeat the procedure for the remaining three
MCV assemblies and MCV seat assemblies.
EN06. MAINTENANCE
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06.4 INSPECTION
1. Inspect the piston assembly for signs of wear, such
as grooves or etching.
2. Replace the piston seal if broken or worn.
2.1. Remove the top and bottom piston seal (item
19) using a plastic pry tool.
2.2. Place replacement seal rings around the piston
assembly (item 21).
2.2.1. Slide the top piston seal ring over the top
of the piston assembly. Ensure the tabbed
side faces down.
2.2.2. Slide the bottom piston seal ring over the
bottom of the piston assembly. Ensure the
tabbed side faces up.
2.2.3. Clasp the rings together.
2.3. 300 cc dispense pump only: Once the piston
seal is attached, roll the seal’s edges on the
table to help minimize its size. This ensures the
piston assembly can fit into the 300 cc cylinder.
3. Inspect dispense pump components for debris,
damage, and wear.
3.1. Include dowel pins (item 11), MCV assemblies
(item 13), and MCV seat assemblies (item 12)
in the inspection.
3.2. If MCV assemblies or seat assemblies are
damaged, order a new set. The spare parts kit
does not include these parts.
4. Inspect O-rings for rips, tears, distortion, and signs of
chemical damage (e.g., discoloration or swelling).
NOTICE
Ensure the metal tabs on the replacement seal rings
face each other upon installation to complete the seal.
CAUTION
Avoid damaging the metal tabs on the piston seal
components.
EN 06. MAINTENANCE
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5. Replace damaged O-rings as needed. The following
steps include replacing all O-rings, which may not be
necessary for every dispense pump inspection.
5.1. Replace the O-ring on the seal holder (item 5).
5.1.1. Remove the damaged O-ring using a seal
puller or hook.
5.1.2. Grease the O-ring groove on the seal
holder.
5.1.3. Apply a new 2-015, solvent-proof O-ring
(item 7).
5.2. Replace any damaged O-rings on the fluid
tubes (item 18).
5.2.1. Remove the damaged O-ring using a seal
puller or hook.
5.2.2. Grease the O-ring groove on the fluid
tube.
5.2.3. Apply a new 2-010, KALREZ O-ring (item
14) to the fluid tube.
5.2.4. Repeat for any other damaged O-rings on
the fluid tubes.
5.3. 600 cc dispense pump only: Replace damaged
o-rings on the cylinder adapters (item 16).
5.3.1. Remove the damaged O-ring using a seal
puller or hook.
5.3.2. Grease the O-ring groove on the cylinder
adapter.
5.3.3. Apply a new 2-027 Perfluoroelastomer
O-ring (item 17) onto the cylinder adapter.
5.3.4. Repeat for the other cylinder adapter if
necessary.
NOTICE
Replace damaged O-rings. Not all O-rings must be
replaced unless they are all damaged.
NOTICE
Ensure the o-ring stays in the grooved boundary.
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5.4. Replace any damaged O-rings on the top block
(item 10) and bottom block (item 22).
5.4.1. Using a seal puller or hook, remove the
damaged O-ring on the bottom of the top
block (where the dispense pump cylinder
rests).Grease the O-ring groove on the top
block.
5.4.2. Grease the o-ring in the groove on the top
block.
5.4.3. Apply a new 2-020 Perfluoroelastomer
O-ring (item 15) to the top block.
5.4.4. Using a seal puller or hook, remove the
damaged O-ring on the top of the bottom
block.
5.4.5. Grease the O-ring groove on the bottom
block.
5.4.6. Apply a new 2-020 Perfluoroelastomer
O-ring (item 15) to the bottom block.
06.5 ASSEMBLY
1. Install seal holder assembly into the top block (item
10).
1.1. Insert one rod seal (item 6) into the top block.
Ensure the side of the seal with the O-ring is
facing up.
1.2. Apply lubricant to the O-ring on the seal holder
assembly.
1.3. Insert the seal holder assembly into the top
block.
1.4. Using a 5/16 Allen wrench, press the seal
holder assembly into the block until it clicks into
place. The top of the seal holder assembly will
be below the lip of the seal housing flange.
1.5. Insert the top rod seal (item 6) into the seal
holder assembly. Ensure the O-ring on the rod
seal is facing down to complete the seal with
the bottom rod seal.
CAUTION
Use a flat edged tool to push the seal holder assembly
into place. Avoid using sharp or pointed tools that could
damage the part
EN 06. MAINTENANCE
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2. Insert the flat washer (item 4) and snap ring (item 3)
into the top block (item 10).
2.1. Place the flat washer on top of the rod seal.
Ensure the washer is fully seated in the
assembly.
2.2. Using the snap ring tool, pinch the ends of the
snap ring together.
2.3. Place the pinched snap ring on the washer.
2.4. Release to snap the ring into place. Ensure the
entire ring is secure and below the lip of the top
block rod seal assembly port.
3. 600 cc dispense pump only: Install one cylinder
adapter (item 16)
3.1. Apply lubricant to the O-ring around the cylinder
adapter.
3.2. Apply lubricant to one flat side of the cylinder
adapter.
3.3. Apply lubricant to the circular groove on the
bottom block (item 22).
3.4. Place the lubricated side of the cylinder adapter
onto the bottom block and press it firmly into
the groove.
3.5. Apply lubricant to the remaining flat side of the
cylinder adapter and the circle within it.
3.6. Repeat the procedure to install the cylinder
adapter in the top block.
4. Apply lubricant to the four O-rings on the two fluid
tubes (item 18).
5. Place the two fluid tubes (item 18) into the grooves on
the bottom block (item 22).
NOTICE
Flat washers typically wear and distort during use.
Rebuild the dispense pump with a replacement and
dispose of the previously used washer.
NOTICE
Ensure the snap ring is snapped into place.
EN06. MAINTENANCE
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6. Install the cylinder (item 20) and piston assembly
(item 21) into the dispense pump.
6.1. Insert the piston assembly into the cylinder with
the side closest to the piston seal (item 19)
facing down.
6.2. Rest the cylinder in the circular groove on the
bottom block (item 22).
6.3. Push the cylinder into place.
6.4. Push the piston assembly down by hand until
the first piston seal is inside the cylinder.
6.5. Tap the piston assembly with a mallet to push
the assembly further into the cylinder.
7. Install the top block (item 10).
7.1. Ensure the top block and bottom block(item 22)
align.
7.2. Align the holes in the bottom of the top block
with the fluid tubes (item 18) and cylinder (item
20).
7.3. Push the top block down. If necessary, adjust
the fluid tubes to fit in their respective holes on
the top block.
7.4. Press firmly until the cylinder and fluid tubes
are in place.
7.5. Check for damaged or trapped O-rings.
NOTICE
Ensure no pieces of the o-ring are cut or trapped
between the cylinder and block
NOTICE
Ensure not to bend the piston seals outward or snag
them onto the cylinder.
NOTICE
Verify the orientation of the top and bottom blocks is
similar before pushing them together.
EN 06. MAINTENANCE
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8. Secure the dispense pump assembly with the socket
head cap screws (item 23).
8.1. Lubricate the end threads of the four socket
head cap screws (1/4-20 x 5.5 LG).
8.2. Insert the screws through the holes in the
bottom block (item 22) toward the top block
(item 10).
8.3. Tighten all four bolts with a 3/16 Allen wrench.
8.3.1. Rotate the upper left bolt clockwise.
8.3.2. Rotate the bottom right bolt clockwise.
8.3.3. Rotate the bottom left bolt clockwise.
8.3.4. Rotate the upper right bolt clockwise.
8.3.5. Repeat until snug.
9. Thread the hex jam nut (1/4-28, part item 2) onto the
drive assembly, but do not tighten it.
10. Attach the pump rod adapter (item 1) to the dispense
pump assembly.
10.1. Thread the pump rod adapter onto the tip of the
drive assembly.
10.2. Secure an 11 mm wrench to the jam nut and a
13 mm wrench to the pump rod adapter.
10.3. Hold the pump rod adapter in place. Move the
jam nut clockwise to lock the pieces together.
NOTICE
Do not tighten the jam nut until the pump rod adapter is
on the drive assembly.
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11. Pull the pump rod out to the length recorded during
disassembly (section 06.2).
12. Install the four MCV assemblies (item 13) into the top
block (item 10) and bottom block (item 22).
12.1. Apply lubricant inside the port on the end of the
block.
12.2. Apply lubricant to the MCV seat assembly (item
12), including the threads and O-ring.
12.3. Insert the MCV seat assembly into the port.
12.4. Using a 5/16 Allen wrench, tighten the MCV
seat assembly.
12.5. Apply lubricant to the threads and O-rings of
the MCV assembly using a Q-tip.
12.6. Insert the MCV assembly into the port.
12.7. Place the MCV tool into the indentations in the
MCV assembly.
NOTICE
Tighten the MCV seat assembly into place carefully,
without breaking the o-ring. If the o-ring breaks, remove
the assembly and replace the o-ring
EN 06. MAINTENANCE
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12.8. Secure an adjustable wrench to the MCV tool.
12.8.1. If using an adjustable torque wrench, the
recommended torque setting for the MCV
tool is 15-20 in/lb.
12.8.2. Turn the wrench clockwise to tighten the
MCV assembly into the port until snug.
12.8.3. The MCV assembly should be nearly flush
with the side of the block.
12.9. Repeat the procedure to install the remaining
three MCV seat assemblies and MCV
assemblies.
13. Refill oil gauges.
13.1. Refill FEP tubing (item 8) with DeVilbiss SSL-
10 gun oil.
13.1.1. Insert the tip of the bottle containing the oil
into one tube end and press down to seal
the bottle tip with the tubing.
13.1.2. Fill the dispense pump with oil until the oil
comes almost to the top of the gauge on
the opposite side of the top block.
13.1.3. Remove the bottle and allow the liquid
levels in the tubes to even out. Add
additional grease to the tubes until they
are a little over half full.
13.2. Attach the end caps (item 9) to the FEP tubing.
06.6 DISPENSE PUMP INSTALLATION
1. Ensure the pump rod adapter (item 1) is the same
distance from the housing flange as when removed.
2. Attach the pump rod adapter (item 1) to the coupler
on the machine.
2.1. Thread the coupler onto the rod adapter by
hand.
2.2. Place a 21 mm wrench on the coupler and a 13
mm wrench on the rod adapter.
2.3. Move the wrenches outward (away from each
other) to tighten the coupler and rod adapter
until snug.
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3. Attach coupling to pump rod.
3.1. The front coupling component has holes for the
screws to enter. The back coupling component
has smaller holes for the screws to exit.
3.2. Place the back coupling on the back of the
pump rod.
3.3. Ensure coupling aligns with the dowel pins
(item 11) on the top block (item 10) and with the
locator pins on the machine.
3.4. Place the front coupling on the pump rod.
3.5. Hold the halves of the coupling tightly and
wiggle the dispense pump gently until they
close. The connection should be tight.
4. Screw coupling halves together.
4.1. Place screws in each of the four screw
positions.
4.2. Using a 4 mm Allen wrench, tighten the screws
in a star pattern:
4.2.1. Rotate the upper left screw clockwise.
4.2.2. Rotate the bottom right screw clockwise.
4.2.3. Rotate the bottom left screw clockwise.
4.2.4. Rotate the upper right screw clockwise.
4.2.5. Repeat until snug.
5. Reattach the pressure sensors.
6. Reattach the inlet and outlet hoses.
EN 07. MANUAL REVISIONS
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MANUAL CHANGE SUMMARY
Date Description Version
05/01/2025 Initial Release R1
07. MANUAL REVISIONS
EN07. MANUAL REVISIONS
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EN 09. WARRANTY
WARRANTY POLICY
This product is covered by Binks’ materials and workmanship limited warranty.
The use of parts or accessories from sources other than Binks will void all warranties. Failure to follow reasonable
maintenance guidance provided can invalidate the warranty.
For specific warranty information, please contact Binks.
For technical assistance or to locate an authorized distributor, contact one of our international sales
and customer support locations listed below.
www.binks.com 77-3167 R1 (05/2025) 33 / 33
REGION BINKS CONTACT
Americas Tel: 1-800-992-4657
Europe, Africa, Middle East Tel: +4401202571111
India marketingroa@binks.com
China Tel: +862133730108
Korea Tel: +82313663303
Japan Tel: +81457856421
Australia Tel: +61085257555
WARRANTY PAGE
08. WARRANTY
EN
Binks is a global leader in innovative finishing technologies.
Binks reserves the right to modify equipment specifications without prior notice.
Binks®, DeVilbiss® and Ransburg® are registered trademarks of Binks US, LLC.
©2025 Binks US, LLC. All rights reserved.
03 SAFETY
03.1 SAFETY PRECAUTIONS
03.2 ADDITIONAL SAFETY INFORMATION
04. introduction
04.1 Dispense pump specifications
04.2 dispense pump PARTS LIST
05. dispense pump servicing
05.1 general tips
05.2 general troubleshooting
05.3 preventative maintenance
05.3.1 Daily maintenance
05.3.2 monthly maintenance
05.3.3 as needed maintenance
06. maintenance
06.1 preliminary procedures
06.2 dispense pump removal
06.3 dispense pump disassembly
06.4 inspection
06.5 assembly
06.6 dispense pump installation
07. manual revisions
08. warranty
