Binks 41-38045 User manual

Binks 4.5:1 EXEL
AIR POWERED PUMP
POSITIVE PRIME RECIPROCATING
HORIZONTALLY OPPOSED 4 BALL PUMP
– WATERBORNE COMPATIBLE –
Replaces
Part Sheet
77-2872R
Part
Sheet
77-2872R-1
INDEX
1. General Information.......................... 2
2. Safety Information
2.1. Safety Warnings.......................... 3
2.2. Fire/Explosion Hazards .............. 5
2.3. Pressure Relief Procedure .......... 5
3. Installation
3.1. Typical Installation...................... 6
3.2. Flush Pump.................................. 8
3.3. Start and Adjust Pump .............. 8
4. Specifications & Operation .............. 9
5. Maintenance
5.1. Parts List ...................................... 10
5.2. Exploded View ............................ 11
5.3. Disassembly ................................ 12
5.4. Re-assembly ................................ 13
5.5. General Maintenance ................ 17
6. Troubleshooting ................................ 18
PROP 65 WARNING
WARNING: This product contains chemicals
known to the State of California to cause
cancer and birth defects or other
reproductive harm.
CA PROP
65

2
SECTION 1 – GENERAL INFORMATION
The pump models listed in the following declaration of conformity may be used in some potentially explosive atmospheres ONLY when the
special conditions for safe installation and operation have been followed as expressed in this user manual (Part Sheet). These models are
approved to ATEX regulations 94/9/EC, protection level: II 2 G X: Suitable for use in Zones 1 and 2.
EC Declaration of Conformity
Manuf. By: Binks
195 Internationale Blvd.
Glendale Heights, IL 60139
Type/Series: Excel 4.5:1 Air Powered Pump
Model: 41-38045, 41-39045
The equipment to which this document relates is in conformance with the following standards or other normative references:
EN ISO 12100-1&2:2003 and thereby conform to the protection requirements of Council Directive 98/37/EC relating to
Machinery Safety Directive, and;
BS EN 1127-1, BS EN 13463-1:2001, and thereby conform to the protection requirements of Council Directive 94/9/EC relating
to Equipment and Protective Systems for use in Potentially Explosive Atmospheres, protection level II 2 G X.
Approved By: ______________________________ Date: ____________
Chuck McCulloch, Binks
Binks reserves the right to modify equipment specification without prior notice.
May 30, 2007
The Binks Exel Pumps have horizontally opposed positive
displacement pistons connected to a common reciprocat-
ing air motor piston. The air driven piston trips the pilot
valves at the end of its travel producing an air logic signal
to shift a spool valve, thus initiating the opposite stroke.
The mechanically tripped pilot valves are reset by a pos-
itive air signal from the exhaust circuit. Additionally, the
pilot valves are spring assisted to ensure consistent, reli-
able operation. The spool valve is piloted and contains
two exhaust ports. Both the pilot valves and the spool
valve “un-bolt” as a cartridge, but can also be disassembled
for repair /service.
The air logic and exhaust ports are completely internal.
Simply mounting the spool valve and the pilot valves
ensures that the logic circuits are connected properly.
The “4-Ball” term refers to the two sets of ball checks.
Each “set” has an inlet and outlet check. In practice, the
inlets are connected by a common inlet manifold and the
outlets are connected by a common outlet manifold.
The “4-Ball” concept primes the pump with the piston
always engaging the seal. Unlike some other horizontally
opposed piston pumps, the piston does not pull free of
the displacement chamber piston seal to allow prime.
Pulling free of the piston seal for prime is lost motion.
No displacement is possible from the time the piston
pulls free and then re-enters the seal. The positive
displacement “4-Ball” concept ensures positive prime
and increased displacement with less energy demands.
This eliminates wasted effort which requires higher air
consumption to displace a given volume of fluid.
Covered by U.S. Patent Nos.
5,094,596/5,415,531/5,655,778
Standard Model w/Hard Chrome Plated Pistons 41-38045
Extreme Duty Model w/Ceramic Coated Pistons 41-39045
Ratio: 4.5:1
GPM/LPM (60 cycles) 6.85/25.93
Maximum Working Pressure (PSI) 450
Maximum Working Pressure (Bar) 31

SECTION 2.1 – SAFETY WARNINGS
3
WARNING
!
In this part sheet, the words WARNING, CAUTION and NOTE are used to emphasize important safety information as follows:
CAUTION
Hazards or unsafe practices which could
result in minor personal injury, product
or property damage.
!
WARNING
Hazards or unsafe practices which could
result in severe personal injury, death or
substantial property damage.
!
NOTE
Important installation, operation or
maintenance information.
Read the following warnings before using this equipment.
FOR FURTHER SAFETY INFORMATION REGARDING BINKS AND DEVILBISS EQUIPMENT,
SEE THE GENERAL EQUIPMENT SAFETY BOOKLET (77-5300).
READ THE MANUAL
Before operating finishing equipment, read and
understand all safety, operation and maintenance
information provided in the operation manual.
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.
KNOW WHERE AND HOW TO SHUT OFF THE
EQUIPMENT IN CASE OF AN EMERGENCY
Refer to the equipment operation instructions for
specific details.
PRESSURE RELIEF PROCEDURE
Always follow the pressure relief procedure in the
equipment instruction manual.
NOISE HAZARD
You may be injured by loud noise. Hearing
protection may be required when using this
equipment.
HIGH PRESSURE CONSIDERATION
High pressure can cause serious injury. Relieve all
pressure before servicing. Spray from the spray
gun, hose leaks, or ruptured components can
inject fluid into your body and cause extremely
serious injury.
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.
WEAR SAFETY GLASSES
Failure to wear safety glasses with side shields
could result in serious eye injury or blindness.
DE-ENERGIZE, DISCONNECT AND LOCK OUT ALL
POWER SOURCES DURING MAINTENANCE
Failure to De-energize, disconnect and lock out
all power supplies before performing equipment
maintenance could cause serious injury or death.
OPERATOR TRAINING
All personnel must be trained before operating
finishing equipment.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equip ment to
rupture, malfunction, or start unexpectedly and
result in serious injury.
KEEP EQUIPMENT GUARDS IN PLACE
Do not operate the equipment if the safety
devices have been removed.
PROJECTILE HAZARD
You may be injured by venting liquids or gases
that are released under pressure, or flying debris.
PINCH POINT HAZARD
Moving parts can crush and cut. Pinch points are
basically any areas where there are moving parts.

4
INJECTION HAZARD
1. The sprayer pumps coatings at high pressure.
If you spray yourself or anyone else at close
range, the stream of material can puncture
the skin and cause great harm (possible
amputation).
2.  point the spray gun at yourself or
anyone else. The tip guard provides some
protection against injection injuries, but is
mainly a warning device.  remove
the tip guard.  point the spray gun
at your hands, fingers, or body. 
keep the spray gun trigger safety catch
locked in the  position when not in use.
3.  cover the tip guard and attempt to
“blow back” fluid. This is not an air sprayer.
4. If injury occurs, see your doctor
immediately! 
. Inform your doctor
specifically of what fluid was injected.
AVOID STATIC SPARKING
Static electricity charge builds up by high
velocity liquid flowing through a hose during
flushing, cleaning, or spraying operations.
Proper grounding of the airless system safely
dissipates this charge.
All high pressure airless systems must be
grounded to avoid dangerous static sparking,
explosion, or fire when spraying or flushing
with flammable liquids.
1. Use Binks  conductive hose in all
airless spraying operations. Be sure gun and
hose have continuity. Check continuity
weekly with ohmmeter. Overall (end to end)
resistance of unpressurized hose must not
exceed 29 megohm (max.) for any coupled
length or combination of hose lengths.
2. Make sure the pump is grounded.
 operate the unit when it is on a
non-grounded platform.
3. When flushing or cleaning with a
combustible solvent, always use an open
metallic container for receiving the waste
solvent. Ground the solvent receptacle.
4. Bond the spray gun to the waste container
with a grounding wire. Be sure there is good
metal to metal contact.
5.  remove spray tip when flushing
the system. Operate the pump at the lowest
possible pressure.
GENERAL WARNINGS
1.  leave a pressurized sprayer
unattended.
2.  use fluids, coatings, or chemicals
that are not compatible with nylon hoses.
3. Be sure that all fluids and solvents to be used
are chemically compatible with the wetted parts
in the pump and fluid handling equipment.
4. Periodically inspect all hoses for leaks
and/or abrasions and tighten all connections
before use. 
 a defective hose.  it
with another conductive hose.
5. Follow all warnings and precautions of the
coating and solvent manufacturers.
6.  relieve pressure in the system by
turning bypass valve to  or
triggering spray gun before disassembly of
any component parts.
REPLACEMENT PARTS
The pump is designed to use authorized parts
only. When using this pump with parts that do
not comply with the minimum specifications
and safety devices of Binks, the user assumes
all risks and liabilities.
AIR AND LUBE REQUIREMENTS
"*)*,-&)+
1. Filtered air will allow the pump to operate
more efficiently and yield a longer life to
operating parts and mechanisms.
2. Use an air regulator on the air supply to
control the pump cycle rate. This will help to
prolong the life of the pump.
3. Apply factory-approved 41-4458- grease to
all air logic components for smooth operation.
TRANSPORT AND STORAGE
1. Store in a dry place; do not remove product
from box during storage.
2. Do not remove protection caps from inlet and
outlet prior to installation.
3. Do not drop or damage box; handle with care.
HIGH PRESSURE CAN CAUSE SERIOUS INJURY IF EQUIPMENT IS INSTALLED OR USED INCORRECTLY—
READ, UNDERSTAND, AND OBSERVE ALL WARNINGS AND INSTRUCTIONS IN THIS MANUAL.
INSTALL, OPERATE OR SERVICE THIS EQUIPMENT ONLY AFTER
ALL INSTRUCTIONS ARE CLEARLY UNDERSTOOD.
It is the responsibility of the employer to place this information into the hands of the operator.
WARNING
!
Bonding Wire,
Gun To Solvent Container
Conductive Hose
To Airless Pump
Open
Metallic
Waste Solvent
Container,
Grounded
CAUTION
Hazards or unsafe practices which could
result in minor personal injury, product
or property damage.
!
WARNING
Hazards or unsafe practices which could
result in severe personal injury, death or
substantial property damage.
!
NOTE
Important installation, operation or
maintenance information.
WARNING
EXCESSIVE AIR PRESSURE
Can cause personal injury, pump damage
or property damage. Do not exceed
maximum inlet air pressure as stated on
motor model plate.
!
CAUTION
Never store de-ionized, distilled, reverse
osmosis or any pure grade of water in the
pump. These fluids may cause corrosion.
!
NOTE
Be sure that all fluids, solvents and fillers
to be used are chemically and physically
compatible with wetted parts in the Exel
pump. Consult your BINKS representative
for Exel pump materials of constructions
and compatibility information. Consult
the fluid manufacture for information
regarding the fluids to be used.
NOTE
BINKS is not responsible for misapplica-
tion of Exel pumps. Consult your BINKS
representative for application assistance.

SECTION 2.2 – FIRE OR EXPLOSION HAZARD
SECTION 2.3 – PRESSURE RELIEF PROCEDURE
5
GROUNDING THE PUMP
Installation of the ground wire attachment to a metallic
portion of the pump must ensure a secure metal-to-metal
contact. The ground wire must be 12 gauge minimum.
A clamp must be attached to a true earth ground and an
instrument test must be done to verify a ground.
Mounting/grounding is the user’s responsibility
TEMPERATURE CONSIDERATIONS
Under normal operating conditions, the flow of material
through the pump will keep it cool.
SAFETY CONSIDERATIONS
The Exel Pump has no exposed moving parts that can
create possible hazards to personnel. However, there are
some safety points to consider:
1. Exhausting air from a motor cycling with the mufflers
removed can exceed OSHA limits. Thus, never operate
the pump without proper muffling.
2. Never attempt to loosen or remove fluid hoses, or to
disassemble the pump without first performing the
pressure relief procedure described below.
3. Never perform any disassembly procedure unless the
air motor air supply has been turned off, the residual air
has been exhausted, and the pressure in the air motor
has been vented. Should air pressure remain within the
motor chamber, the motor could cycle at any time.
4. If the manifold is not in place, keep hands and fingers
clear of the pump manifold fluid inlet and the individual
inlets. The powerful suction can cause serious bodily
injury, and any breaks in the skin can allow exposure
to the chemicals in the formulation being pumped.
5. Pressure relief procedure must be followed whenever
the pump is shut off for cleaning, servicing, or repair-
ing any part of the air or fluid system. This includes
removing/installing or cleaning spray gun tips or nozzles.
1. Engage the spray gun safety latch or dispensing valve
lockout control.
2. Turn off the air supply.
3. Disengage the spray gun safety latch or dispensing
valve lockout control
4. Hold a metal part of the gun or valve firmly in contact
with a grounded metal (only) waste container. Now
trigger the gun to relieve fluid pressure.
5. Engage spray gun safety latch again.
6. Open the pump drain valve (required in system); use
the container to capture the drainage.
7. Allow the drain valve to remain open until you are
ready to spray again.
WARNING
To reduce the risk of serious bodily injury from moving parts, fluid injection, and
splashing in the eyes or on the skin, always follow this procedure whenever the
pump is shut off; when checking, repairing, or servicing any part of the system;
when installing or charging spray nozzles; and whenever spraying is stopped.
!
NOTE
Ground Wire Kit is included!
Use Binks Ground Wire Kit #41-13021
IMPORTANT
If you have reason to suspect that the spray nozzle or hose is clogged or that
all residual pressure cannot be fully relieved after following the above steps,
VERY SLOWLY, loosen the hose end coupling with a wrench and relieve pressure
gradually, then loosen completely. If the nozzle or hose obstruction cannot be
cleared completely, or is suspect, replace the nozzle or hose. Do not reuse.
NOTE
If the fluid to be pumped is heated, then the pump will
assume the temperature of the heated fluid.
WARNING
Do not let the pump run dry. A dry pump will run excessively
fast and will generate heat that will damage pump components
and create hot surfaces.
!

SECTION 3.1 – TYPICAL INSTALLATION
6
WALL MOUNT BRACKET 207-12328
Two brackets provide a
wall mount pattern of
5-1/2" (5.5") vertical by
6-5/8" (6.625") horizontal.
5.5"
[140]
6.625"
[168]

7
SECTION 3.1 – TYPICAL INSTALLATION
14
18
17
16
1513
11
10A
12
10
9
8
7
6
5
4
3
2
1
The general arrangement of a typical installation as
depicted in the diagram is advisory only.
Be sure to mount the pump securely and to position the
pump above the floor at a convenient height to allow for
maintenance, visual observation, and periodic inspection.
Use a compatible thread compound on all tapered male
pipe threads to guard against leakage and to lubricate
threads for assembly.
The wall mount bracket is included with all Exel pumps.
Pump geometry positions air valve and outlet manifold to one
side, allowing wall mounting without the need for a shelf.
1. Oil-water extractor
2. Piping circuit to avoid scale and resolve
3. Air valve bleed type master
4. Oil-water extractor
5. Regulated air pressure gauge
6. Air regulator self relieving
7. In-line oiler
8. Air valve bleed type shut-off
9. Grounded air supply line
10. Automatic drain
10A. Automatic drain-away hosing
11. Pump protector device
12. Outlet filter
13. Grounded fluid line
14. Pressure relief-drain valve
15. Pressure relief-drain hosing
16. Siphon tube hosing with spring guard (optional)
17. Hosing/piping from gravity supply (optional)
18. Ground wire connected to ground source
NOTE
The mounting of the pump to a vertical surface or wall may
require reinforcement back-up. Please contact your Binks
Representative for assistance in planning your system. Be
sure that you comply with all federal, state, and local codes
before installation.

8
SECTION 3.2 – FLUSH PUMP BEFORE INSTALLATION
SECTION 3.3 – START AND ADJUST PUMP
Numbers i pare theses ( ) refer to drawi g o page 7.
1. Place the suction hose (16) in the fluid to be pumped.
2. Close the fluid drain valve (14).
3. With the regulator (5) closed, open both bleed-type air
valves (3) & (8).
4. Open the fluid control device while continuing with
the following steps.
5. Slowly open the air regulator (5). Adjust it about 5 PSI
(0.3 Bar) at a time until the pump runs smoothly.
6. Cycle pump slowly until all air is purged out of the
lines (fluid flowing in a steady stream from the fluid
outlet) until the pump is primed.
7. If you are purging:
a. Slowly cycle pump enough to thoroughly clean both
the pump and hoses.
b. Close the gun or fluid control dispensing device and
air regulator (5).
c. Back off air regulator until the gauge reads zero.
d. Remove the suction hose (16) from the solvent and
place it in the fluid to be pumped.
8. Placing the pump in service
a. Start the pump. Be sure the suction hose is in the
supply container and the tube end is below the fluid
level.
b. Read all pressure warnings in this manual and follow
the pressure Relief Procedure on page 5. Trigger the
gun into a grounded metal waste container to prime
the hose. Be sure that the correct spray tip is
installed in the gun. Adjust the pump pressure just
enough to completely atomize the fluid. Higher pres-
sures are unnecessary and only cause premature noz-
zle and pump wear.
c. A pump in a dead end system will cycle upon
demand only.
d. A pump in a circulating system runs continuously
and speeds up or slows down as supply demands.
9. Removing the pump from service.
a. Flush the pump thoroughly before shutting down,
especially if pumping a material that will react with
time or heat.
b. Remove the siphon hose from the supply container
and cycle the pump to force fluid out of the system.
Prime the pump with a compatible solvent and shut
off the air supply.
c. Follow the Pressure Relief Procedure Warning on
page 5.
The pump was factory tested with lightweight oil. Some
residue is left in to protect the pump parts. If this could
contaminate the fluid you are pumping, flush it thoroughly
with a compatible solvent. To start the pump, follow the
procedure in the following section, ,*,'#-+,
-&).
WARNING
To reduce the risk of fluid injection injury, static sparking,
and splashing, read and follow safety instructions on pages
3 through 5 of this part sheet.
!
WARNING
NEVER allow the pump to run dry of fluid. A dry pump can
accelerate to a high cycle speed, possibly damaging itself.
If the pump accelerates quickly, or is running too fast, stop
it immediately. If the pump is empty and air has been
pumped into the lines, refill the container and again prime
the pump and lines. A pump protector valve is available.
!
NOTE
Check all fittings. Be sure they are tight. Be sure to use
PTFE tape, which is compatible with all fluids, on all male
pipe threads.

SECTION 4 – SPECIFICATIONS & OPERATION
9
!"++"&)%""0%*(+++,"('"%%-+,*,+
,!',*"*&(,(*/",!1'&"!&*
())(+"+)%&',)"+,('+'(-*%%
!$*"'")%
1. As the pistons move to the right, the lower
left check is opened. Fluid is drawn in
through the bottom inlet and into the left
block. Fluid is also returned from the left
dynamic chamber to the inlet check.
2. The right block is now pressurized and the
upper right check is opened. Fluid is expelled
from the pump outlet. As this happens, fluid
is also drawn into the right dynamic chamber,
keeping the seal wet.
3. At this stage of the stroke, the upper left and
lower right checks are closed to keep the
fluid flowing towards the pump outlet.
The Exel “Dynamic” Pump incorporates bellows seals
between the dynamic chamber and the air motor. The
pump should not be pressure fed or even gravity fed.
Pressure fed Exel Dynamic Pumps could experience
bellows failure.
NOTE
Excessively high cycle rates may cause bellows failure.
Only operate in the recommended range.
Ratio: 4.5:1
Maximum Recommended Cycle Rate:
20 cycles per minute – Continuous Duty
40 cycles per minute – Intermittent Duty
Capacity/Displacement @ 60 CPM:
6.85 GPM [25.93 LPM] (See Chart)
Maximum Air Input Pressure: 100 PSI [6.9 Bar]
Inlet Size, Air: 1/2 NPT(f)
Inlet Size, Fluid: 1" Sanitary
Outlet Size, Fluid: 1" Sanitary
Air Requirement at 60 cycles per minute and 100 PSI:
28.0 CFM [793 LPM]
dB (A) noise Levels:
Air Motor tested at 100 psi [6.9 Bar], 30 cycles per minute, (loaded)
Distance from pump dB (A)
Background 70
25 feet 73
10 feet 78
6 inches 87
SPECIFICATIONS
Wetted Parts:
300 Series S.S.
400 Series S.S.
Tungsten Carbide
UHMW-PE
PTFE
Hard Chrome (41-38045)
Ceramic (41-39045)

10
SECTION 5.1 – PARTS LIST
1 207-11660 AIR MOTOR CYLINDER .................... 1
2 207-10731 AIR MOTOR PISTON ........................ 1
3 41-4433 䡲AIR MOTOR PISTON SEAL .............. 1
4207-10732 AIR MOTOR STUD .......................... 1
5 237-64 䡲O-RING ............................................ 2
6 41-4407 AIR MOTOR COVER PLATE ............ 2
7 41-4445 䡲ROD SEAL ASSEMBLY ...................... 2
8 41-4446 䡲ROD WEAR RING ............................ 2
9 207-11949 ALIGNMENT RING .......................... 2
10 207-11947 PISTON ROD .................................... 2
11 41-4412 䡲BELLOWS SEAL ................................ 2
12 207-12080 RETAINING NUT .............................. 2
13 41-4402 DYNAMIC CHAMBER ...................... 2
14 41-4414 䡲DYNAMIC CHAMBER SCREW SEAL .... 8
15 20-6134 䡲SOCKET HEAD CAP SCREW ............ 8
16 41-4403* MATERIAL PISTON (HARD CHROME) .... 2
16 41-4432** MATERIAL PISTON (CERAMIC) ............ 2
17 41-4415 䡲PISTON BOLT SEAL .......................... 2
18 20-6793 䡲HEX HEAD CAP SCREW .................. 2
19 41-4408 䡲MATERIAL PISTON SEAL .................. 2
20 41-4401 OUTPUT BLOCK .............................. 2
21 237-559 䡲WASHER .......................................... 8
22 20-6104 䡲SOCKET HEAD CAP SCREW ............ 8
23 20-6648 䡲O-RING (TEF) ...................................... 12
24 41-4409 SEAT (TUNGSTEN CARBIDE) .................... 4
ITEM PART
NO. NO. DESCRIPTION QTY.
33 237-155 WASHER .......................................... 20
34 237-179 SOCKET HEAD CAP SCREW ............ 20
42 237-672 SOCKET HEAD CAP SCREW ............ 4
46 237-539 SOCKET HEAD CAP SCREW ............ 4
ITEM PART
NO. NO. DESCRIPTION QTY.
AIR MOTOR HARDWARE KIT 41-4453
3 41-4433 AIR MOTOR PISTON SEAL .............. 1
5 237-64 O-RING ............................................ 2
7 41-4445 ROD SEAL ASSEMBLY ...................... 2
8 41-4446 ROD WEAR RING ............................ 2
38 237-542 O-RING ............................................ 12
39 237-507 PUSHROD SEAL ................................ 2
43 237-62 O-RING ............................................ 4
44 237-63 O-RING ............................................ 2
41-37042 AIR CONTROL SEAL KIT .................. 1
41-37043 PILOT VALVE SEAL KIT .................... 2
ITEM PART
NO. NO. DESCRIPTION QTY.
AIR MOTOR SOFT SEAL KIT 41-4455
207-10864 T-RING SEAL .................................... 5
237-53 O-RING ............................................ 2
237-542 O-RING ............................................ 6
(REFER TO PART SHEET 77-2799 FOR DETAILS)
ITEM PART
NO. NO. DESCRIPTION QTY.
AIR CONTROL SEAL KIT 41-37042
(FOR USE WITH ITEM NO. 45)
237-544 O-RING ............................................ 3
237-543 O-RING ............................................ 3
237-617 WAVE WASHER .............................. 1
*ONE 41-37043 KIT IS NEEDED FOR EACH PILOT VALVE
(REFER TO PART SHEET 77-2799 FOR DETAILS)
ITEM PART
NO. NO. DESCRIPTION QTY.
PILOT VALVE SEAL KIT 41-37043
(FOR USE WITH ITEM NO. 41)*
15 20-6134 SOCKET HEAD CAP SCREW ............ 8
18 20-6793 HEX HEAD CAP SCREW .................. 2
21 237-559 WASHER .......................................... 8
22 20-6104 SOCKET HEAD CAP SCREW ............ 8
28 41-4452 SCREW .............................................. 16
ITEM PART
NO. NO. DESCRIPTION QTY.
FLUID SECTION HARDWARE KIT 41-4454
17 41-4415 PISTON BOLT SEAL .......................... 2
19 41-4408 MATERIAL PISTON SEAL .................. 2
23 20-6648 O-RING (TEF) ...................................... 12
29 41-4416 DYNAMIC TUBE GASKET ................ 8
35 41-4417-K10 SANITARY FLANGE GASKET (10-PACK) 1
ITEM PART
NO. NO. DESCRIPTION QTY.
FLUID SECTION SOFT SEAL KIT 41-4456
11 41-4412 BELLOWS SEAL ................................ 2
14 41-4414 DYNAMIC CHAMBER SCREW SEAL .... 8
ITEM PART
NO. NO. DESCRIPTION QTY.
BELLOWS KIT 41-4457
25 20-4963 BALL ................................................ 4
26 41-4404 BALL CAGE ...................................... 4
27 41-4405 FLANGE ADAPTER .......................... 4
28 41-4452 䡲SCREW .............................................. 16
29 41-4416 䡲DYNAMIC TUBE GASKET ................ 8
30 41-4418 DYNAMIC PLUG .............................. 4
31 41-4420 DYNAMIC TUBE RETAINER ............ 4
32 41-4419 DYNAMIC TUBE .............................. 2
33 237-155 䡲WASHER .......................................... 20
34 237-179 䡲SOCKET HEAD CAP SCREW ............ 20
35 41-4417-K10 SANITARY FLANGE GASKET ............ 4
36 41-4411 MANIFOLD ...................................... 2
37 41-4431 SANITARY CLAMP .......................... 4
38 237-542 䡲O-RING ............................................ 12
39 237-507 䡲PUSHROD SEAL ................................ 2
40 207-10753 PUSHROD ........................................ 2
41 207-11308 䡲PILOT VALVE ASSEMBLY ................ 2
42 237-672 䡲SOCKET HEAD CAP SCREW ............ 4
43 237-62 䡲O-RING ............................................ 4
44 237-63 䡲O-RING ............................................ 2
45 41-4441 ▲AIR CONTROL VALVE ASSEMBLY .... 1
46 237-539 䡲SOCKET HEAD CAP SCREW ............ 4
47 207-12328 MOUNTING BRACKET .................... 2
48 41-13021 STATIC GROUND KIT (NOT SHOWN) .... 1
49 41-4448 ADAPTER, 1" SANITARY x 1" NPT(F)
(PURCHASE SEPARATELY)
ITEM PART
NO. NO. DESCRIPTION QTY.
䡲Items not available separately. Order kits below.
*Hard chrome coated piston supplied with 41-38045 Standard Pump.
** Ceramic coated piston supplied with 41-39045 Extreme Duty Pump.
▲Reference Part Sheet 77-2799 for further detail.
PARTS LIST
When ordering, please specify Part No.

SECTION 5.2 – EXPLODED VIEW
11
GLIDE-RING
O-RING
ITEM 2 – AIR MOTOR PISTON
ITEM 3
DETAIL
GLIDE-RING
ITEM 6 – COVER PLATE
ITEM 10 – PISTON ROD
O-RING
ITEM 7
DETAIL
INCLUDED, BUT NOT SHOWN: 41-13021 Static Ground Kit
Binks MODELS 41-38045-STANDARD DUTY / 41-39045 EXTREME DUTY STAINLESS STEEL PUMP
ITEM 39
NOTE ORIENTATION OF
ITEM 39

12
SECTION 5.3 – DISASSEMBLY
Numbers i pare theses ( ) refer to the exploded view
drawi g o page 11.
FLUID SECTION
1. Follow the Pressure Relief Procedures and Warnings
on page 4.
2. Disconnect the air and fluid lines, remove the pump
from its mounting, and place it on a shop bench. A vise
will be necessary for this procedure.
3. Mount pump using the integral air motor mounting
pads. Use all four holes!
4. Remove the outlet and siphon manifolds (36) from the
pump by loosening/ removing the sanitary type clamps
(37). During removal, capture the sanitary seals (35) as
the manifolds come away from the pump. Inspect the
sanitary seals and replace if damaged or worn. Note:
the inlet (siphon) and outlet manifolds are identical.
5. Remove the four socket head cap screws (22) and
washers (21) that secure the output block (20) to the
dynamic chamber (13).
6. Loosen the dynamic tube retainer (31) on the flange
adapter (27) so that the fluid section components will
slide away from the dynamic tube (32). Gently wiggle
the fluid section (block with ball cages and flange
adapters attached) until it is free from the piston seal
and place on the work bench.
Step 7 is required o ly for mai te a ce o balls a d seats.
7. Remove the four socket head cap screws (28) that hold
each flange adapter (27) and ball cage (26) to the output
block. Carefully remove the flange adapters and ball
cages taking care not to drop or damage the ball (25) or
the seat (24) inside. Note the seat orientation.
28
27
26
25
24
20
23
Remove fluid section
as a unit
Items 21 & 22
Item 31
NOTE
The upper and lower ball cages and flange adapters are
identical. Each ball cage has an arrow indicating the proper
flow direction. Also, the PTFE o-rings (23) should be replaced
when the fluid section is rebuilt.

13
SECTION 5.3 – DISASSEMBLY
SECTION 5.4 – RE-ASSEMBLY
AIR MOTOR
1. When re-assembling air logic seals and o-rings in the
air control valve and the pilot valves use only factory
approved grease: Binks part number 41-4458- .
2. If new air motor shaft seals (7) and wear rings (8) are
required, install them into the air motor end plates (6).
No lubrication is required. The orientation of the shaft
seals is shown on p. 11.
3. The air motor piston seal (3) is a 2-piece seal. It is
designed for long life. If a new seal is required, install
as shown on p. 11. No lubrication is required.
4. Insert air piston assembly (2,3,4,10) at a slight angle
into the air motor cylinder (1), then straighten.
Pre-lubricate and carefully install the cover plate
o-rings (5, 43). Be sure that they are seated firmly.
The bolts should be tightened snugly (10 ft-lb).
Do not over tighten.
5. Insert the pilot valve push rod making sure that it is
seated properly. Pre-lubricate the o-rings (38) and cup
seals (39) using factory approved grease (41-4458- )
and install. See p. 11 for orientation of the pushrod
cup seals (39).
DYNAMIC CHAMBER & BELLOWS
8. Remove the piston seal (19) and set it into the block.
The seal should be examined for possible damage.
Now remove the piston retaining bolt (18) and seal
(17) and slide the piston (16) off the rod (10).
9. Remove the four socket head cap screws (15) that
secure the chamber (13) to the air motor cover plate
(6). Remove the dynamic chamber (13) by carefully
guiding it over the bellows (11). Place the chamber
aside with the four screws. Replace the four dynamic
chamber screw seals (14) during re-assembly.
10. Optio al – The dynamic tube (32) may be removed
from the dynamic chamber (13) for cleaning or
inspection of the dynamic tube seal (29). To do so,
loosen the dynamic tube seal (31) on the dynamic
chamber (13) so that the dynamic tube (32) will slide
away from the chamber. Inspect the seal and replace
if necessary.
11. Remove the bellows retaining nut (12) and remove
bellows (11) from the shaft (10).
Slide alignment ring (9) off shaft (10).
AIR MOTOR
12. With an extended hex socket key, remove the pilot
valve assembly (41) by removing the socket head cap
screws (42). Remove the three o-ring seals (38).
13. Remove the pushrod (40) and pushrod seal (39) from
the air motor cover plate (6) and inspect the seal for
wear. Note orientation of pushrod seal shown on p.
11.
14. The disassembly of the pilot valve is necessary on an
occasional basis to check for possible wear and dam-
age (refer to Part Sheet 77-2799).
15. Remove the air control valve (45) by removing the
four socket head cap screws (46). Careful removal
will prevent the possible loss of o-ring seals that may
fall out.
16. To disassemble the air control valve refer to Part
Sheet 77-2799.
17. The air motor cover plate (6) is held to the air motor
with ten hex head cap screws (34). With the screws
removed, the cover plate can then be slid off the pis-
ton rod (10). Be careful not to damage the shaft seals
(7) and wear rings (8) housed in the air motor cover
plate bore.
18. The air motor shaft seals (7) and wear rings (8) locat-
ed in the air motor cover plate bore should seldom
require replacement. When replacement is required,
carefully remove the existing seals and wear rings
with a pick.
19. Pull or push the air piston assembly (2,3,4,10) at a
slight angle from the air cylinder (1). Inspect the pis-
ton seal (3) for excessive wear or damage and replace
if required.
NOTE
Bellows may need to be cut from the shaft.

14
6. Install the pilot valve assembly (41) using the two
socket head cap screws (42).
7. Pre-lubricate the o-rings for air logic circuits. Install
the pre-lubricated o-rings into their appropriate ports
on the air motor: the pilot valve ports (38), the air
motor-to-piston ports (44), exhaust ports (43), and,
finally, the rest of the pilot valve ports.
8. Carefully align the air control valve and secure with
four socket head cap screws (46). Tighten to 8-10 ft-lbs.
DYNAMIC CHAMBER & BELLOWS
9. %%(/+++&%1 Slide the alignment ring (9)
over shaft (10) and then install the bellows seal (11)
over the piston rod shaft (10). The bellows has a small
rib that will snap into the outermost groove in the pis-
ton rod. Carefully slide the bellows over the rod until it
snaps into the first groove. DO NOT push the bellows
past the first groove. When the bellows is in place it
should be approximately 1-5/8" from the end of the
shaft as shown. Grasp the bellows seal with your left
hand and hold firmly while starting and hand tighten-
ing retaining nut (12) until tight. Using a 1" deep sock-
et continue to tighten nut until it touches the bellows
shoulder. Stop as soon as the nut touches the bellows.
DO NOT OVERTIGHTEN.
10. Install the chamber (13) making sure that it seats
properly over the bellows (11). Next install the four
socket head cap screws (15) with nylon washers (14).
Torque to 30 ft-lb.
11. If the dynamic tube (32) was removed from the
dynamic chamber during disassembly, replace the
tube gasket (29) and slide the dynamic tube nut (31)
over the tube. Assemble into the lower port of the
dynamic chamber (13).
SECTION 5.4 – RE-ASSEMBLY
NOTE
It is strongly recommended to test run the air motor before
proceeding.
NOTE
Bellows seal becomes self threading by the nut (12). After
installation, nut should just touch the bellows shoulder.
10
911 12
Approx.
1-5/8"
Snap rib into
1st groove
Nut should just
touch bellows –
NO FURTHER!

15
SECTION 5.4 – RE-ASSEMBLY
12. Install the piston (16) into the chamber and secure
with the retaining bolt (18) and bolt seal (17). Torque
the piston bolt to 40-50 ft-lbs. Make sure that the
shaft does not twist when the pistons are assembled
and tightened to the shaft. THE BELLOWS MUST
NOT TWIST. Have an assistant place a wrench on the
opposite shaft to hold the shaft still while the retain-
ing bolt (18) is tightened.
FLUID SECTION
If Fluid Sectio s were disassembled, re-assemble
as follows:
13. Replace the PTFE o-rings (23) in the output blocks
(20), ball cages (26), and flange adapters (27). Insert
balls (25) and seats (24) into the ball cages as shown.
Refer to page 17 for correct ball/seat orientation.
14. The flange adapters (27) to be used on the outlet side
of the pump require a plug (30) and gasket (29). If the
plug (30) has been leaking, replace the gasket (29)
and retighten the plug (30).
15. On the inlet and outlet side of the block, assemble
flange adapter (27) to ball cage (26) containing the
ball (25) and seat (24) – note seat orientation – and
install loosely onto pump with socket head cap
screws (28). Be sure that all Teflon o-rings (23) have
been put into place.
16. Insert screws (28) and secure the items to the block.
Do not fully tighten yet. The flange adapter should be
able to slide back and forth slightly.
Replace fluid sectio as a u it:
17. Replace the dynamic tube seals (29) on the inlet
flange adapter (27). Slide a dynamic tube nut (31)
onto the dynamic tube (32) that is mounted on the
dynamic chamber (13). The fluid section can now be
attached to the pump as a unit.
18. Seat the piston seal (19) into the output block (20)
making sure that the lip is directed into the block.
NOTE
Bellows must not twist during assembly.
INSTALL FIRST PISTON
INSTALL SECOND PISTON
Place wrench at flats on shaft and hold
while other side is tightened.
Place wrench on piston bolt hex and
hold while other side is tightened.
PTFE

16
SECTION 5.4 – RE-ASSEMBLY
PISTON SEAL
PRESSURIZED
CHAMBER
AIR MOTOR
Carefully place the block with the seal over the pis-
ton. Press firmly until the block seats on the chamber
(13). Install the four hex head cap screws (22) with
washers (21) and tighten to 30 ft-lb.
19. Reattach the manifolds (36) using the sanitary clamps
(37). Make sure that the sanitary gaskets (35) are in
place. Lightly secure the sanitary clamps and make
sure that the flange adapters (27), sanitary gaskets
(35), and manifolds (36) all fit properly. Tighten the
socket head cap screws (28) using a ball end hex key
to secure the final position of the flange adapters.
Release the sanitary clamps (37) and remove the
manifolds (36). Take care to catch the sanitary gaskets
(35) if they fall. Tighten the socket head cap screws
(28) to 18 ft-lbs. using a torque wrench. Reinstall the
sanitary gaskets (35) and manifolds (36) and securely
tighten the sanitary clamps (37).
20. Tighten the dynamic tube nuts (31) securely.
NOTE
Lip of piston’s seal should face toward pressurized chamber
(away from air motor).

17
SECTION 5.5 – GENERAL MAINTENANCE
Flush the Pump with a
Compatible Solvent
1. Flush often enough to extend life
of piston seal and to prevent fluid
from drying in the pump with
possible damage.
2. ALWAYS flush before storing.
a. If you had been pumping a water
based fluid, flush the pump with
BIN S Pump Purj prior to stor-
age. Follow all Pump Purj label
instructions. Residual Pump
Purj will prevent corrosion.
Flushing with Mineral Spirits or
with another compatible solvent
prior to storage is also an option.
b. Leave the Binks Pump Purj in
the pump to protect the pump
parts from corrosion.
3. For maximum protection, be sure to
eliminate all air from the system.
4. Be sure that all solvents used are
chemically compatible with the
wetted parts in the pump and with
the fluids being pumped.
Tighten Threaded Connections
1. Check all hoses before each use
for wear or damage and replace as
necessary. Be sure all threaded
connections are tight.
2. Check and tighten all threaded
connections, including manifold
screws, clamps, plugs, and valve
screws at least every six months.
Check and Service the
Regulator and Filter
1. Follow service instructions supplied
with air control components.
2. To reduce icing due to excessive
water in the air supply, use ethylene
glycol anti-freeze.
Double Sided Seats
Binks Exel pumps have double sided tungsten carbide seats installed at the factory in the tapered edge orientation
(below left). This orientation is optimal for most types of coatings. However, if a highly viscous or filled material is
used, the seats may be flipped over for use in the sharp edge orientation (below right). Be sure to note orientation
when disassembling and reassembling the pump.
CAUTION
Never run this pump dry (without
material) for prolonged periods of
time. Running the pump dry creates
heat and friction, which could damage
some of the internal parts, causing
pump failure. Improper operation of
the pump will void your warranty.
!
CAUTION
Never store de-ionized, distilled,
reverse osmosis, or any pure grade of
water in the pump. These fluids may
cause corrosion.
!
WARNING
To reduce the risk of fluid injection, static
sparking, and splashing, read and follow
Flushing Safety under FIRE OR EXPLOSION
printed earlier in this part sheet.
!

WARNING
!
SYMPTOM
No test is possible. Best economy is to assume o-
ring is faulty.
Air is getting into the intake housing:
a. Defective o-ring on intake
manifold.
b. Suction hose/tube not sealed.
Worn piston Seals.
Foreign matter in ball checks or bad ball checks.
Replace o-ring. Tighten connections.
Replace piston seals.
Inspect, clean and/or replace balls and seats.
Pump will not prime
TEST PROCEDUREPROBABLE CAUSE REMEDY
Pump will not run
Visually observe. Start nearest the pump to
ascertain/locate all valves.
Visually observe. Start nearest the pump to
ascertain/locate all valves.
Recommended minimum air pressure regulator 20
psi (1.95 bar), depending on fluid being pumped.
Switch/interchange pilot valves to isolate faulty
pilot valve.
Check for constant exhaust air when pump is not
running.
Constant exhaust noise.
Air supply is turned off.
Fluid valve is turned off.
Air pressure regulator adjustment too low.
Pilot valve assemblies inoperable. Needs servicing.
Air piston seal worn.
Air control valve defective.
Turn air supply on.
Turn fluid supply on.
Increase air pressure regulator adjustment.
Repair or replace pilot valve assembly.
Replace seal.
Repair or replace air control valve.
Pump runs but
does not maintain
constant pressure
Check for spitting at fluid outlet.
Pump fast cycles on one end of stroke. Indicates
that side is bypassing.
Air in fluid line.
Air line undersized; too long or restrictive fittings;
hose is crimped.
Obstructed or worn ball and seat.
Worn piston seals.
Bleed fluid line until constant flow is
obtained.
Install larger air line, minimum size 1/2".
Correct fitting sizes rectify hose path.
Remove, clean, and inspect/reverse seat, ball,
and ball cage. Replace if suspect or worn.
Replace piston seals.
Air exhaust noise
at junction of
static chamber and
air motor on
pump prime stroke
Stall pump on prime stroke to isolate noise.
If noise stops on opposite stroke, only that
seal is faulty.
Pump fast cycles on one end of stroke. Indicates
that side is bypassing.
Check for slow air flow at muffler.
Pump reacts slowly.
Check for sluggish air control valve operation.
Worn/failed air motor shaft seal(s).
Worn/failed/loose air motor shaft seal components.
Worn fluid piston and/or seal.
Air control valve mufflers plugged.
Air control valve dirty or worn.
Failed/worn seals.
Excessive or lack of lubrication.
Dirty air passages.
Disassemble pump as required to replace all
seal components on BOTH sides.
Replace piston and/or seal.
Remove and clean mufflers or replace.
Repair or replace air control valve.
Repair or replace seals.
Adjust lubrication.
Clean air passages; Service air line filter
and/or control valve filter.
SECTION 6 - TROUBLESHOOTING
Component rupture can cause serious bodily injury. NEVER
exceed 125 psi (8 bar) air supply pressure to the pump.
Read the warning section printed earlier in this part sheet.
BEFORE DISASSEMBLING THE PUMP, check and consider all
probable causes and follow Pressure Relief Procedure on
page 5.
Damaged Bellows
Deformed bellows noticed when maintenance
is performed. A damaged bellows may also
leak fluid which will be noticed during normal
operation.
Bellows installed incorrectly
Cycle rate is too high.
When installing bellows, take extreme care
not to twist, deform or damage bellows
Do not run the pump above the recommend-
ed operating range. Damage to the bellows
and piston seals is likely to occur.
7/11 © 2011 Binks All rights reserved. Printed in U.S.A.
U.S.A./Canada Customer Service
195 Internationale Blvd.
Glendale Heights, IL 60139
630-237-5000
Toll Free Customer Service
and Technical Support
800-992-4657
Toll Free Fax
888-246-5732
Binks Sales and Service: www.binks.com
WARRANTY
This product is covered by Binks’ 1 Year Limited Warranty.

BOMBA DE AIRE COMPRIMIDO
EXEL 4.5:1 DE BINKS
BOMBA DE 4 BOLAS CON ÉMBOLOS
OSCILANTES PARA CEBADO POSITIVO
– COMPATIBLE CON DISPOSITIVOS TRANSPORTADOS
POR AGUA –
Hoja de
piezas
77-2872R-1
ÍNDICE
1. Información general.......................... 20
2. Información de seguridad
2.1. Advertencias de seguridad ........ 21
2.2. Peligros de incendio/explosión .. 23
2.3. Procedimiento de reducción
de presión .................................. 23
3. Instalación
3.1. Instalación típica ........................ 24
3.2. Purgar la bomba ........................ 26
3.3. Activar y ajustar la bomba ........ 26
4. Especificaciones y operación ............ 27
5. Mantenimiento
5.1. Lista de piezas ............................ 28
5.2. Vista de los componentes .......... 29
5.3. Desensamblaje ............................ 30
5.4. Reensamblaje.............................. 31
5.5. Mantenimiento general ............ 35
6. Localización y reparación
de averías .......................................... 36
Sustituye
hoja de piezas
77-2872R
ADVERTENCIA PROP 65
ADVERTENCIA: Este producto contiene sustancias
químicas que según información en poder del
estado de California producen c ncer, defectos de
nacimiento y otros daños al sistema reproductor.
PROP
65
DE CA

20
SECCIÓN 1 – INFORMACIÓN GENERAL
Los modelos de bomba listados en la siguiente declaración se pueden utilizar en algunas atmósferas potencialmente explosivas ÚNICAMENTE
cuando se han seguido las condiciones especiales para la instalación y la operación seguras como se expresa en este manual de usuarios (Hoja
de piezas). Estos modelos est n aprobados para regulaciones ATEX 94/9/EC, nivel de protección: II 2 G X: Aptos para uso en las Zonas 1 y 2.
Declaración de conformidad EC
Fabricado por: Binks
195 Internationale Blvd.
Glendale Heights, IL 60139
Tipo/Serie: Bomba de aire compromido Exel 4.5.1
Modelo: 41-38045, 41-39045
El equipo con el cual se relaciona este documento cumple con las siguientes normas u otras referencias normativas:
EN ISO 12100-1 y 2:2003 y por consiguiente cumple con los requisitos de protección de la Directiva del Consejo 98/37/EC relacionada con la
Directiva de Seguridad de Maquinaria, y:
BS EN 1127-1, BS EN 13463-1:2001, y por consiguiente cumple con los requisitos de protección de la Directiva del Consejo 94/9/EC relacionada
con Equipos y Sistemas Protectores para uso en Atmósferas Potencialmente Explosivas, nivel de protecciónII 2 G X.
Aprobado por: ___________________________________ Fecha: ___________________
Chuck McCulloch, Binks
Binks se reserva el derecho de modificar la especificación del equipo sin previo aviso.
30 de mayo de 2007
Las bombas Exel de Binks tienen émbolos de desplazamiento
positivo opuestos horizontalmente conectados a un émbolo
oscilante del motor de aire comprimido común. El émbolo
accionado por aire dispara las válvulas piloto al final de su
desplazamiento produciendo una señal lógica de aire para
desplazar una válvula de carrete, iniciando así el
recorrido opuesto.
Las válvulas piloto accionadas mecánicamente son reposi-
cionadas por una señal de aire positiva del circuito de escape.
Asimismo, las válvulas piloto tienen resortes para asegurar la
operación sistemática y confiable. La válvula de carrete es
dirigida y contiene dos lumbreras de escape. Tanto las válvulas
piloto como la válvula de carrete se “desabulonan” como un
cartucho, pero también se pueden desmontar para reparaciones
o servicio de mantenimiento.
Las aberturas del circuito lógico y los orificios de escape son
completamente internos. Sencillamente montar la válvula de
carrete y las válvulas piloto asegura que los circuitos lógicos
sean conectados debidamente.
El término “4 bolas” se refiere a los dos juegos de válvulas de
retención de bola. Cada “juego” tiene una válvula de admisión y
de salida. En la práctica, las válvulas de admisión están conec-
tadas por un colector de admisión común y las de salida están
conectadas por un colector de salida común.
El concepto de las “4 bolas” ceba la bomba con el émbolo
siempre enganchando el obturador. A diferencia de otras bom-
bas de émbolo horizontalmente opuestos, el émbolo no hala
para liberar el obturador del émbolo de la cámara de desplaza-
miento para permitir el cebado. Halar para liberar el obturador
del émbolo para cebar es movimiento perdido. Ningún
desplazamiento es posible desde el momento que el émbolo
hala para liberar el obturador y luego vuelve a entrar en el obtu-
rador. El concepto de “4 bolas” con desplazamiento positivo
asegura el cebado positivo y un mayor desplazamiento con
menos demandas de energía. Esto elimina el desperdicio de
esfuerzos que requiere de un mayor consumo de aire para
desplazar un volumen dado de fluido.
Cubierto por las Patentes estadounidenses números
5,094,596/5,415,531/5,655,778
Modelo est ndar c/Émbolos cromados duros 41-38045
Modelo de rendimiento extremo c/Émbolos
revestidos con material cer mico 41-39045
Coeficiente: 4.5:1
GPM/LPM (60 ciclos) 6.85/25.93
Presión de trabajo m xima (PSI) 450
Presión de trabajo m xima (Bar) 31