Binks HP 4/32 User manual

Product Description
Safety Instructions
Operating Instructions
for
BINKS
Airless Model HP 4/32
These operating instructions are part of the equipment. Please read and follow all
instructions and safety precautions before using the equipment. Disregarding can
causes injuries on people and/or damages on the unit.
ITW Oberflächentechnik GmbH & Co. KG
Justus-von-Liebig-Straße 31, 63128 Dietzenbach, Deutschland
Telefon [phone] / 403-1 Telefax +49 (0) 6074 / 403-281
Internet www.itw-finishing.de
ITW Finishing Systems and Products
Ringwood Road, Bournemouth BH11 9LH, England
Phone [phone] / 571111 Telefax +44 (0) 1202 / 581940
Internet www.itweuropeanfinishing.com
ITW Surfaces et Finitions
163-171 Avenue des auréats BP 1453, 26014 Valence Cedex France
Téléphone [phone] Fax [phone]
Internet www.itweuropeanfinishing.com
Edition 09/05

2
TABLE OF CONTENTS
1. DESIGNATED USE............................................................................................................3
2. BRIEF DESCRIPTION.......................................................................................................4
3. TECHNICAL DATA............................................................................................................7
4. SAFETY................................................................................................................................8
4.1 Principle of operation; intended use....................................................................8
4.2 Safe working conditions..........................................................................................8
4.3 Particular danger spots............................................................................................10
5. START UP AND OPERATION.........................................................................................11
5.1 Grounding the BINKS airless pump.....................................................................11
5.2 Preparing to start up the BINKS airless pump...................................................11
5.3 Rinsing the BINKS airless pump...........................................................................12
5.4 Preparing and adjusting the spray material........................................................13
5.5 Start-up.........................................................................................................................13
5.6 Work stoppages.........................................................................................................14
6. SHUT-DOWN ......................................................................................................................15
7. CLEANING YOUR BINKS UNIT......................................................................................15
8. MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIAL MEASURES...............16
8.1 Compressed air supply unit....................................................................................16
8.2 Pneumatic drive and control system unit............................................................16
8.3 Spray material pump unit.........................................................................................17
8.4 Suction system unit..................................................................................................17
9. INSTRUCTION MANUAL..................................................................................................18
10. COMPULSORY TESTING................................................................................................18
11. TEST DOCUMENTS..........................................................................................................19
12. SPARE PARTS LISTS......................................................................................................20
13. RECOMMENDED GUN.....................................................................................................43
14. EC DECLARATION OF CONFORMITY.........................................................................44
15. WARRANTY STATEMENT.....................................................................................45

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1. DESIGNATED USE
BINKS airless pumps are used exclusively to output and apply spray material. Any materials can be
sprayed, if they are approved by spray material manufacturers for use with airless spraying equip-
ment. These include:
•Water-thinnable lacquers and paints
•Solvent-based lacquers and paints
•Base paints and primers
•Micaceous iron ore
•Zinc-rich paints
•Epoxy and polyurethane paints
•Oils
•Liquid synthetic materials
•Wax-based underbody sealant materials
•Low-solvent and solvent-free spray material
Please observe the working guidelines and safety instructions supplied by the spray material manu-
facturer.
You should avoid using abrasive, granular spray material. Such spray material can
cause heavy wear and tear on the valves and packing sets of the material pump, and
on the nozzles used on the airless gun.
ATTENTION !
BEFORE STARTING UP PUMP FILL UP LUBRICATION FLUID
FOR WATERBORNE PAINT: 0114-014871
FOR SOLVENT PAINT: 0114-009433

4
2. BRIEF DESCRIPTION (FIGURE 1)
1Pneumatic drive 11
High pressure filter
2Compressed air supply connection piece 12
High pressure filter relief valve
4Spray material pump 13
Return pipe
5Suction system 14
Grounding terminal
7Compressed air control valve 15
Spray material outlet connection piece
8Pressure reducer 16
Grounding terminal (if used without HP-filter)
10
Release agent chamber

5
Comments on figure 1
The pneumatic drive (1) drives the BINKS airless pump. An airflow controller in the pneumatic drive
applies compressed air alternately to the pneumatic drive butt plate. This sets the butt plate moving
upwards and downwards.
The pneumatic drive is flange-mounted directly to the spray material pump (4). A moving axle con-
nects the pneumatic drive butt plate to the double piston of the spray material pump.
The ascending stroke of the double piston draws in the spray through the suction system (5) and
the foot valve of the spray material pump. At the same time, the material spray, which is already in
the spray material pump above the double piston, is ejected through a check valve into the high
pressure filter (11).
The descending stroke of the double piston closes the foot valve and the spray material which has
been drawn in, is forced through a plunger valve into the space above the double piston. At the
same time, the spray material which is already there is ejected into the high pressure filter.
If the airless gun take-off is not operative, counter pressure will build up in the spray material line.
The pump will stop. Remove spray material from the airless gun and the BINKS airless pump will
start up again.
The area of the butt plate is greater than the area of the double piston. This difference in area
causes the pressure to intensify. With an area ratio of 60/1, for example, a working pressure of 1
bar at the pneumatic drive will be intensified to a working pressure of 60 bar at the spray material
pump.
The release agent chamber (10) physically separates the butt plate of the pneumatic drive from the
double piston of the spray material pump. The release agent chamber is filled with release agent
(Order Code 0114-014871 for waterborne paint, Order Code 0114-009433 for solvent paint). The
release agent cleans the double piston of the spray material pump and lubricates the packing and
the moving axle.
The volume of air and thus the delivered volume of spray material is regulated by the working pres-
sure at the compressed air control valve (7). The compressed air control valve is equipped with an
excess pressure safety valve, which is triggered if the maximum working pressure at the pneumatic
drive is exceeded.
The spray material pump can draw in spray material in two ways.
Direct suction:
This involves immersing the suction system in the spray material.
Suction through a flexible suction system:
This involves connecting the spray material pump to a flexible suction system. The free end of the
suction system is inserted into the tank containing the spray material.

6
The extracted spray material is filtered through the high pressure filter (standard filter on HP 4/32:
type 03 -order-no. 0110-009130), before being driven out through the spray material line and the
airless gun. We recommend the following filter cartridges for the various types of spray material:
Filter size Nozzle Spray material
M 200 less than 0.3 mm colourless lacquer
M 150 greater than 0.3 mm surfacer, filler, red lead
M 100 greater than 0.3 mm surfacer, filler, red lead
M 70 greater than 0.5 mm micaceous iron ore, red lead
M 50 greater than 0.6 mm emulsion, loaded spray material
Do not use a filter cartridge for fibre-loaded spray material!
HD filter cartridges (overview)
Filter-type
Order-no. 01 0114-013525 01 0114-013525 02 0110-009057 03 0110-009130 11 0114-011760 13 0114-013585
Filter-type
Order-no. 05 0114-013526 05 0114-013526
Screen area 29 cm227 cm249 cm284 cm2118 cm2118 cm2
Core material polyamide brass stainless steel stainless steel polyamide no filter core
Figure 2

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3. TECHNICAL DATA
BINKS HP 4/32
Theoretical
transmission 32 : 1
Air motor Air intake pressure 8 bar
Diameter cylinder 85 mm
Material pump Volume double stroke 27 ccm
Operating pressure max. 256 bar
Piston stroke 75 mm
Free flow capacity nominal 1,6 ltr./min.
Piston diameter D1 15 mm
Piston diameter D2 21,5 mm
Connections Air inlet Stem for quick disconnection
or R 3/8" (m)
Air to gun (Aircombi only) 90° connection for hose 8x6
or 1/4" NPS (m)
Fluid outlet on HP-filter
1/4" NPS (m)
Dimensions of
bare pump Lx W x D in mm 580 x 165 x 120
The nameplate on your outfit is attached to the spray material pump. Enter the data from the name-
plate into figure 3. Have this information ready when you call customer service.
Figure 3
Phone: [phone] / 403-1
Telefax: +49 (0) 6074 / 403-281
E-Mail: [e-mail]
http://www.itw-finishing.de

8
4. SAFETY
As well as the operating instructions and the applicable legal and other mandatory regulations
relevant to accident prevention in the country of use and at the place of use, you must also
observe the recognised special engineering regulations governing safe and professional
working practices.
4.1 PRINCIPLE OF OPERATION; INTENDED USE
1. BINKS airless spraying equipment has been built to comply with state-of-the-art standards and
recognised safety rules. Nevertheless, its use may constitute a risk to life and limb for the user
or for third parties, or cause damage to the BINKS airless pump and other assets.
2. The BINKS airless pump must only be used in technically perfect condition in accordance with
the regulations and the instructions set out in the operating instructions and only by safety-
conscious persons fully aware of the risks involved. Any malfunctions, especially those affect-
ing safety, must be rectified immediately. The spray material line must not be dragged across
sharp-edged objects and must always be checked before use to ensure that it is in perfect
condition.
3. BINKS airless pumps are designed exclusively for the designated use stated in Section 1. Us-
ing them for purposes other than those mentioned is considered contrary to the intended use.
The manufacturer/supplier cannot be held liable for any damage resulting from such use. The
user alone must bear the risk.
4. The manufacturer is not liable for any unauthorised modifications or repairs made to the
BINKS airless pump.
5. In accordance with the professional association directives governing jet stream units, ZH 1/406,
paint spraying equipment should be checked by experts on request, or at least every 12
months, to ensure that there is no risk involved in its continued operation. If the units are idle,
the examination can be delayed until the next period of operation. The operator is obliged to reg-
ister the equipment for testing and to keep written records of the results of such testing.
4.2 SAFE WORKING CONDITIONS
1. The requirements of the (German) accident prevention and safety regulation “Working with sur-
face coating compounds” (VBG 23) and the (German) directives governing jet stream units (ZH
1/406) and static electricity (ZH 1/200) provided by the professional associations, must be ob-
served.
2. Every person using a BINKS airless pump must have read and understood the operating
instructions, in particular the chapter on “Safety”.
3. If work is to be carried out in enclosed areas, effective, technical ventilation must be provided.
4. Use only those spray material lines and airless guns that are designed for use at the relevant
maximum permitted working pressure of the spray material pump.
5. Be careful that there are no sources of ignition in the vicinity, for example, an open fire, sparks,
glowing wires, hot surfaces, burning cigarettes, etc. There must be a distance of at

9
least 5 m between the spray jet outlet and any possible source of ignition (the spray mist is ig-
nitable and there is a risk of fire or explosion).
6. The spray material leaves the nozzle under pressure. Do not direct the spray jet towards peo-
ple or animals, as this could cause injuries. If the skin is broken and comes into contact with
paint, lacquer or solvent, there is a risk of infection. Consult a doctor immediately to obtain pro-
fessional, expert treatment. Tell the doctor which spray material or solvent is involved. Present
the safety data sheet.
7. Be aware that working with sprays may produce vapours which can damage your health (see
information on the safety data sheet and the tins of material). You must therefore use a per-
sonal breathing equipment, as indicated by the spray material manufacturer. Keep children and
all people right away from the work area.
8. Keep the BINKS airless pump in a safe place to which children and unauthorised persons do
not have access. Make sure that unauthorised personnel (and children in particular) cannot
start up the BINKS airless pump.
9. Store the BINKS airless pump in a dry place.
10. Use only original BINKS accessories and original BINKS replacement parts.
11. Repair work must only be carried out by authorised specialised companies or by ITW
Oberflächentechnik. You can obtain the addresses of specialised companies from ITW
Oberflächentechnik or from your specialised dealer.
12. When repairing and mounting the pump it is necessary that all connections are clean and
mounted correctly.
Before re-starting the pump the correct resistance (1 MO) must be measured.
The resistance has to be determined between foot valve and upper top point of the pump.
13. You must be careful when carrying out spraying work, not to direct the jet towards the
BINKS airless pump unit.
14. Dispose of cleaning and spraying material waste in accordance with the information provided
by the respective spray material and solvent manufacturers.
15. If work is interrupted, to change the nozzle, for example, lock the safety lever on the airless gun.
Release pressure from the system.

10
4.3 PARTICULAR DANGER SPOTS
1. The flow of material escaping from the airless gun is under great pressure and thus has a pow-
erful cutting effect.
You must therefore never point the airless gun at yourself or any other person, animal
or plant. Never touch the spray jet with your fingers or hand, or hold them in front of
the airless gun.
Note:
If the cutting effect of the flow of material causes injury seek medical advice immediately. Tell
the doctor which spray material (paint) and/or solvent (thinners) was involved and provide the
relevant information from the manufacturer as per the safety data sheet (supplier, his phone
number, the material number).
2. The escaping spray material generates recoil power. You must therefore always hold the air-
less gun securely and make sure that you have a well-balanced stance.
3. In enclosed systems, or systems which are under pressure, where aluminium or galvanised
parts come into contact with the liquid, there can be dangerous chemical reactions if 1.1.1 tri-
chloroethane, methylene chloride or other solvents containing halogenated chlorinated hydro-
carbons, are used.
If you use the named solvents or paints which contain these solvents, we recommend that you
contact the spray material manufacturer or ITW Oberflächentechnik.
4. If there are malfunctions or obstructions, you must immediately shut off the compressed air
supply at the ball valve. Disconnect the unit from the compressed air system, operate the air-
less gun and open the high pressure filter relief valve before removing the airless gun or the
hose.
5. To prevent static charging from causing a fire or an explosion, the equipment must be properly
grounded (the pump, the material tank, the object to be coated). If using materials with a flash
point under 21°C (e.g. nitro) of ignition group G1-G3, there must be an additional conductive
connection between the material tank and the pump (potential equalisation cable). The material
tank must always be made of metal.
6. Prevent spray back into a closed tank, as an ignitable gas/air mixture will build up. Take particu-
lar care with materials with a flash point less than 21°C (e.g. nitro).
7. The A-weighted sound level of pumps may exceed 85 dB (A).
Local conditions may dictate a higher noise level, which could cause noise deafness. If this is the
situation, operating personnel must be protected by suitable protective equipment or safety meas-
ures.

11
5. START-UP AND OPERATION
5.1 GROUNDING THE BINKS AIRLESS PUMP
To prevent static charging igniting the flammable spray material, the BINKS airless
pump must be grounded in accordance with professional association regulation
ZH 1/200 (Germany), “Static Electricity”, before it is started up. A grounding cable is
included in the supply schedule.
1. Grounding wire has to be mounted on the grounding terminal of the high pressure filter or (if
pump is used without HP-filter) on the middle section of the pump.
2. Connect the other end of the grounding cable to a suitable grounding device (e.g. grounding bar).
5.2 PREPARING TO START UP THE BINKS AIRLESS PUMP
Proceed as follows:
1. Check that the release agent chamber is full. To do this, open the screw plug on the filler neck
of the release agent chamber. If necessary, top up the release agent (Order Code for solvent
paint: 0114-009433, for waterborne paint: 0114-014871) and close the screw plug again.
2. Select a suitable filter cartridge using the table in section 2, Brief Description and insert it into to
the high pressure filter.
3. Attach a suitable spray material line to the spray material outlet connection piece on the high
pressure filter.
The spray material lines in the BINKS supply programme are identified on the screw
fitting with the maximum permitted working pressure and the bursting pressure. The
lesser value, the maximum permitted working pressure, must be greater than the
maximum permitted working pressure of the spray material pump (see 3, Technical
Data).
4. Connect the airless gun designed at least for the maximum permitted working pressure of the
spray material pump, to the spray material line.
We recommend for Airless: BINKS Airless spray gun HAP 50 with max. pressure 500 bar or
BINKS Airless spray gun Airless 1 with max. pressure 420 bar.
We recommend for Aircombi: BINKS Aircombi spray gun AA 4000 with max. pressure
275 bar or BINKS Aircombi spray gun DSG-2000 with max. pressure 250 bar.
5. Make sure that the ball valve on the pneumatic drive is closed.
6. Connect the compressed air supply at the compressed air supply connection piece.
7. The airless pump is equipped with an air maintenance unit, consisting of filter, pressure regula-
tor and fog lubricator. The air maintenance unit is intended for cleaning compressed air for
workshop purposes from liquid and solid contamination, for pressure regulation and for provid-
ing a fine oil spray for lubrication of cylinders, valves etc.
Set the amount of oil (drops per minute) on the dosing screw as required during operation. The
number of drops can be seen in the sight-glass.

12
The filter cleans the compressed air from water condensate, scale, rustparticles etc.
Drain off the water condensate at regular intervals and clean the sintered filter if it is dirty.
Before putting the pressure line into operation, relieve the filter regulator by fully unscrewing the
regulating screw. Thereafter rotate the regulating screw clockwise until the pressure gauge on
the filter regulator indicates the required pressure (please consider the min. and the max. data -
see section 3 Technical Data).
5.3 RINSING THE BINKS AIRLESS PUMP
Wear eye protection
Every BINKS airless pump is tested with water during final inspection and thoroughly rinsed with a
non-gumming preservative oil. With this rinsing process, it is possible that the residual moisture of
water emulsion will be left in the pump.
Before the unit is started up for the first time, a suitable solvent must be used to thoroughly rinse out
the remains of the preservative fluid and the unavoidable impurities introduced during equipment
assembly.
Proceed as follows:
1. Prepare the BINKS airless pump for start-up in accordance with section 5.2.
2. Close the high pressure filter relief valve.
3. Immerse the spray material pump or the suction system in the tank of solvent.
4. Insert the high pressure filter return pipe into the tank of solvent. Open the high pressure filter
relief valve.
5. Open the ball valve of the air supply and set the compressed air control valve on the pressure
regulator to approximately 1 bar. The spray material pump or the suction system now draws in
the solvent. The solvent runs back to the tank through the high pressure filter, the high pressure
filter relief valve and the return pipe.
6. Point the airless gun into the tank. Unlock the safety lever on the airless gun, operate the air-
less gun take-off and close the high pressure relief valve. The solvent will now flow through the
high pressure filter, the spray material line and the airless gun, back into the tank.
The time of rinsing depends on the length of the material lines and the solubility of the spray
material. We recommend a short reflush with "fresh" solvent.
7. Release the airless gun take-off.
8. Slowly increase the pressure at the compressed air control valve of the pressure reducer to
maximum working pressure (see section 3, Technical Data), while checking and testing that all
lines and screw and plug caps are tightly sealed. If there are any leaks in the system, shut
down the BINKS airless pump immediately. Only re-start the BINKS airless pump once you
have repaired the leak.
9. Reduce the pressure at the compressed air control valve of the pressure reducer again and
close the ball valve.

13
10. Make sure that the return pipe is still directed into the solvent tank. Carefully open the high
pressure filter relief valve to reduce the pressure in the spray material pump and in the high
pressure filter.
11. Point the airless gun into the tank of solvent and operate the take-off, to reduce any pressure
which may still exist in the spray material line and in the airless gun.
If working with waterborne spray material, the BINKS airless pump must again be
thoroughly rinsed with water before it is started up.
5.4 PREPARING AND ADJUSTING THE SPRAY MATERIAL
To be able to work without trouble and obtain a perfect surface, special care must be taken in pre-
paring and adjusting the lacquers and paints (please contact spray material manufacturer).
Before starting to spray, it may be necessary to use the solvent prescribed by the manufacturer to
thin the spray material. Add thinners until, after a good stir, the spray material runs easily off the
stick used for stirring. To prevent any uncertainty, we recommend that you use a dip measuring
cup, where the run-out time of the spray material indicates whether the spray material is still too
thick and therefore whether it is necessary to add more thinners. According to experience, the flow
time for lacquers and paints is 18 to 22 DIN4 sec. and for effect lacquer and coating filler materials
25 to 50 DIN4 sec. These figures relating to DIN EN ISO 2431 and have been established at a tem-
perature of 20°C. The lacquer and paint manufacturers generally state the best spraying consis-
tency for each of their products. If you use motor driven mixers, you must ensure that no air bub-
bles form in the spray material.
To take a measurement, proceed as follows:
Immerse the measuring cup into the lacquer or paint which is ready for spraying until it is full to the
brim. To make the measurement, quickly take out the dip measuring cup and count how many sec-
onds it takes for the entire contents of the cup to run through the 4mm nozzle, i.e. up to the time
when you can establish the break-off point of the out-flowing paint. Count off the seconds on a
wristwatch, or time with a stopwatch. If, for example, a consistency of 19 DIN4 sec. is prescribed,
but the measurement is 24 DIN4 sec., you must add some more thinners and make the measure-
ment again.
We recommend that once you have used it, you clean the dip measuring cup immediately, so that it
can be used again for the next measurement.
Because two filters are used in the BINKS airless unit, a suction filter and the high pressure filter, it
is not necessary to filter the spray material before working with it.
If particularly high-quality coating work is involved, you can also use a gun filter from the BINKS ac-
cessories range.
5.5 START-UP
1. Prepare the BINKS airless pump for start-up in accordance with section 5.2 and if necessary,
rinse in accordance with section 5.3.

14
2. Close the high pressure filter relief valve.
3. Immerse the spray material pump or the suction system in the spray material to be used for
working.
4. Place the high pressure filter return pipe in the tank. Then open the high pressure filter relief
valve.
5. Open the ball valve for the compressed air supply and use the pressure regulator to set the
compressed air supply to 1 bar. The material spray pump will now draw in the spray material.
The spray material flows back into the tank through the high pressure filter, the high pressure
filter relief valve and the return pipe.
6. Point the airless gun into the tank. Unlock the safety lever on the airless gun. Operate the air-
less gun take-off and close the high pressure relief valve. The spray material will now flow
through the high pressure filter, the spray material line and the airless gun, back into the tank.
7. Release the airless gun take-off and set the working pressure at the pressure control valve of
the pressure reducer.3
Before carrying out any coating work, we recommend a test spray (e.g. on to paper or wood). Only
if the test gives you the desired result should you start to coat the actual object.
Make sure that the edges and the fringe areas of the object to be coated are also given an even
coating.
5.6 WORK STOPPAGES
•If working with 2-K spray material, you must note the given pot life and follow it pre-
cisely. Within this time, the unit must be carefully cleaned and rinsed with the rec-
ommended solvent. There must be no residue left in the spray material pump, the
high pressure filters or the airless gun.
•When work is stopped, the safety lever of the airless gun must be locked.
For work stoppages of between 10 and 30 minutes, please proceed as follows:
Wear eye protection
1. Lock the safety lever on the airless gun.
2. Shut off the compressed air supply by closing the ball valve.
3. Briefly open the high pressure relief valve, taking care that the return pipe is not pointed at other
people or at yourself, until the pressure has reduced. Then close the high pressure relief valve
again.
4. Clean the outside of the airless nozzle from spray material residue.

15
6. SHUT-DOWN
Once work is completed, the BINKS airless unit must be thoroughly cleaned. Under no
circumstances must you allow paint residue to dry out in the unit. To clean the airless
unit, use a solvent appropriate to the spray material.
Wear eye protection
1. Close the ball valve for the compressed air supply.
2. Make sure that the return pipe is still directed into the spray material tank. Carefully open the
high pressure filter relief valve to reduce the pressure in the spray material pump and in the high
pressure filter.
3. Point the airless gun into the tank of spray material and operate the take-off to reduce any pres-
sure which may still exist in the spray material line and in the airless gun.
4. Lock the safety lever on the airless gun.
5. Remove the spray material pump or suction system from the spray material.
7. CLEANING YOUR BINKS UNIT
In no case spray material or solvent should soak into the ground or the canalisation.
Wear eye protection
1. Clean the pump and the suction system from the outside. Immerse the spray material pump or
the suction system in the tank of solvent.
2. Clean the fluid tip / tip system as described in the service bulletin of the spray gun. We recom-
mend to stock the fluid tip in solvent.
3. Unlock the safety lever of the airless gun without fluid tip but with mounted tip system or tip
guard. Operate the gun. Close the high pressure filter relief valve. Set the incoming air pressure
to max. 2 bars and open slowly the ball valve. Let the solvent runs through the system so that the
spraying material could rinse out.
4. Let the solvent runs through the system for a couple of minutes until the solvent runs clear
through the airless gun. Close the ball valve and lock the safety lever of the gun
5. Clean the airless gun from the outside and check the filter on the handle (if mounted).
6. Clean the filter insert of the high pressure filter.
7. Clean the filter of the suction pipe.
8. We recommend to remain the equipment filled with liquid.
We recommend to preserve the BINKS airless equipment if it is not used for a longer period of time.
Please rinse the complete system with silicon-free oil as described in section 5.3.

16
8. MALFUNCTIONS, POSSIBLE CAUSES AND REMEDIAL
MEASURES
In case of a break down of your equipment please contact your dealer or the manufacturer of the
unit who will lead a professional repair.
8.1 COMPRESSED AIR SUPPLY UNIT
Type of defect Appearance of de-
fect Possible cause Remedy
No flow through
BINKS airless pump.
Spray material pres-
sure drops.
BINKS airless pump
does not start.
No compressed air.
Nozzle on airless
gun blocked.
Check compressed air
supply.
Clean or replace noz-
zle.
Reduction of area.
Air motor controller
blocked.
Pipeline kinked,
pressure controller
contaminated.
Contaminated com-
pressed air.
Check lines.
Clean pressure control
valve.
Filter compressed air.
8.2 PNEUMATIC DRIVE AND CONTROL SYSTEM UNIT
Type of defect Appearance of de-
fect Possible cause Remedy
Erratic operation,
number of strokes
reduced, pneumatic
drive stops.
Faulty piston valve. Wear.
Foreign matter in the
control system.
Replace parts.
Remove foreign mat-
ter, replace faulty
parts.
Pneumatic drive
frozen up. Compressed air too damp.
Condensation in the
compressed air sup-
ply.
Too many strokes.
Install water separa-
tor.
Check compressor.
Use smaller spray
nozzle.
Modify working condi-
tions.
Install oiler.
Reduce air pressure.

17
8.3 SPRAY MATERIAL PUMP UNIT
Type of defect Appearance of de-
fect Possible cause Remedy
Material coming from
the spray material
chamber.
Upper packing of
spray material pump
faulty.
Replace spray mate-
rial pump packing.
BINKS airless pump
runs non-stop. BINKS airless pump runs on despite stop-
ping spraying.
Lower packing of
spray material pump
faulty
Replace spray mate-
rial packing.
BINKS airless pump
does not stop on
down-stroke.
Foot valve or plunger
valve faulty or stuck. Wear.
Dried material.
Replace parts.
Careful cleaning nec-
essary.
BINKS airless pump
does not stop on up-
stroke.
Foot valve or plunger
valve faulty or stuck. Wear.
Dried material.
Replace parts.
Careful cleaning nec-
essary.
Spray material es-
cape at double piston.
Grooving in the slide
faces. Wear. Replace parts.
8.4 SUCTION SYSTEM UNIT
Type of defect Appearance of de-
fect Possible cause Remedy
BINKS airless pump
works erratically.
Suction screen
blocked. Spray material con- taminated. Clean or replace suc- tion screen.
BINKS airless pump
runs, but there is no
flow.
No suction power. Suction filter dirty.
Foot valve ball sticks
to valve seat.
Suction system not
properly screwed
down.
Spray material pump
draws air, screw
down properly.
Clean.
Make practicable.

18
9. INSTRUCTION MANUAL
Depending on the type of application and the place of installation, the operator must use the operat-
ing instructions to provide more details on the safe operation of the BINKS airless pump, in the form
of an instruction manual in the language of the workforce. This instruction manual is to kept in a
suitable location at the place of work and the workforce informed of its whereabouts. The workforce
should comply with the instructions contained in this instruction manual.
10. COMPULSORY TESTING
In accordance with the professional association directives governing jet stream units, ZH 1/406,
paint spraying equipment should be checked by an expert on request, or at least every 12 months,
to ensure that there is no risk involved in its continued operation. If the units are idle, the examina-
tion can be delayed until the next period of operation. The operator is obliged to register the equip-
ment for testing and to keep written records of the results of such testing.
An expert is someone whose professional training and experience has given him adequate knowl-
edge and understanding of jet stream units and who is sufficiently acquainted with the relevant na-
tional health and safety and work and accident prevention regulations, directives and generally rec-
ognised technical regulations, that he is able to assess whether jet stream units are safe to oper-
ate.
The employer (operator) must make sure that test results for each jet stream unit are kept as a
written record and that this is retained until the next text. We provide a blank "Test record for
spraying equipment" form for this purpose. Please make as many copies of this as you need.
Furthermore, you must ensure that this test document is available at the place where the jet stream
unit is in use. A copy of the test record or a test plaque is sufficient for this.
But we also ask you to enter the test document, date and expert in the “Test Document” table.

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11. TEST DOCUMENTS
Test record for spraying equipment
ITW Oberflächentechnik GmbH & Co. KG
Justus-von-Liebig-Straße 31
D-63128 Dietzenbach
Telefon[phone] / 403-1
Telefax +49 (0) 6074 / 403-281
Date: ..................................
Examiner: ...................................
DEALER STAMP: ADDRESS OF OPERATOR:
Name: ......................................................
Street: ......................…….........................
Postcode/Town: .......................................
Contact:........................................Phone: ...........……..........
Tested unit:
Manufacturer: ..................................................
Type: .........................................................
Eqpt.-No.: ..................................................
Year of manufacture: .................................
System components used:
O Airless pump
O Airless gun
O Spray material line
O Pump head Cart O
Triprod O
Wall bracket O
Tested components complies not tested does not
comply retrofit recom- mended
General condition of system
Jet stream unit
Equipment name plate
Safety valve
Pressure gauge fitting
Pressure relief valve
Jet stream unit with heater
Temperature limitation / control
Temperature display
Spraying device
Max. pressure identification
Equipment number identification
Efficiency
Safety equipment
Hoses and fittings
Hose identification
Fitting identification
Grounding
Between components
Overall system
Measuring of resistance (1 MO)
Operating instructions
Function of the overall system
User instructions
Technical condition
Safe condition
Health and safety at work regulations
Overall assessment of the examination
Comments:

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TEST DOCUMENTS
Test document no. Date of test Expert
Company Name
12. SPARE PARTS LISTS