Binks MACH 2A User manual

MACH 2A Hydraulically-
Assisted Automatic
HVLP Spray Gun
The Binks MACH 2A
Hydraulically-Assisted Automatic
HVLP Spray Gun combines the
proven HVLP efficiency of Binks
best selling MACH 1 Spray Gun
with hydraulically-assisted atom-
ization to yield a reliable, care-
fully engineered special-purpose
spray gun. The MACH 2A pro-
vides consistent coatings with
difficult materials by “preatomiz-
ing” pressurized fluid through a
constrictive carbide nozzle.
Specially designed air nozzles
further promote material atomiza-
tion and ensure consistent, even
finishes.
The MACH 2A operates at high
transfer efficiencies, and fully sat-
isfies the “California South Coast
Air Quality Management
District” requirements for a
“High Volume Low Pressure” air
spray gun. The MACH 2A makes
use of special features to ensure
this compliance – the air inlet
passage incorporates a venturi to
actively limit airflow. The throat
of the venturi converts dense, high
pressure inlet air to high volume,
low pressure atomizing air, and
creates a highly efficient “soft
spray.”
This Part Sheet contains an
exploded drawing and a detailed
parts list to enable a complete
understanding of the spray gun’s
construction. A summary of
spray gun operation, cleaning,
care and maintenance, and trou-
bleshooting common problems is
also provided.
PACKAGE CONTENTS
Please note your Binks MACH 2A
Spray Gun package was shipped
with the following contents.
If anything in the following
list is missing, please call
1-800-992-4657 for a prompt
shipment of the missing item.
1 MACH 2A Spray Gun
1 PART SHEET . . . . . . . . . .2552R-5
1 GUN BRUSH . . . . . . . . .82-469
1 GUNNER’S MATE . . . . . .54-3871
Replaces
Part Sheet
2552R-4
Part
Sheet
2552R-5
1
1
2
3
4
5
6
7
8
23
4
5
6
7
8
FLUID INLET
ATOMIZING AIR INLET - 1/4 NPS
CYLINDER AIR INLET - 1/4 NPS
SIDE PORT CONTROL
MOUNTING HOLE (1/2" Diameter)
MOUNTING LOCK SCREW
AIR NOZZLE ASSEMBLY
NEEDLE COVER (Not Shown)
NOTE
Please be sure to read the
warnings on page 2.
NOTE
IMPORTANT REGULATORY NOTE regarding
the use of this product appears on page 8.

POTENTIAL HAZARD EFFECT PREVENTION
• Use outdoors or ventilate paint area to keep vapors below
explosive, flammable and toxic limits.
• No smoking or open flames.
• No electrical sparks. Ground all metal or conductive objects
WARNING: Can and personnel.
cause serious • Use paints, coatings and solvents compatible with the pump
Flammable, Explosive burns, lung and hoses.
and Toxic Vapors damage or death • Use recommended protective equipment.
• Read Material Safety Data Sheets (MSDS) and container labels.
WARNING: Can • Keep hands and body out of spray and away from
cause serious hose leaks.
cuts or poisonous • Relieve pressure before taking apart or servicing.
High Pressure Spray injections
and Hose Leaks
OVERVIEW OF POTENTIAL HAZARDS
2
The MACH 2A hydraulically-assisted
spray gun uses high pressure to spray
paints and solvents. Since liquids
sprayed at high pressure can cause
injuries, and some paints and solvents
can be toxic or cause explosions and
fires under certain conditions, your
safety and the safety of others depend
on your reading the information in this
Part Sheet.
If you have questions or do not under-
stand the information presented, call
your nearest service representative.
In this part sheet, the words WARNING
and CAUTION are used to emphasize
important safety information. The word:
•WARNING means that severe injury
or death can result from failure to
follow instructions.
•CAUTION means that property dam-
age or injury or death can result
from failure to follow instructions.
The word NOTE is used to indicate
important steps to be followed or
important considerations.
SAFETY INSTRUCTIONS
FIRE AND EXPLOSION
HAZARDS
Volatile fumes in paints, coatings and
solvents can catch fire and even explode
under certain conditions. Volatilization
of fluids, as in paint spray operations,
increases this possibility. Fires and
explosions can occur from excessive
heat, open flames, electrical sparks
from equipment or from static condi-
tions.
For example, paint flowing through
hoses creates a potential for static
charge buildup. You can reduce such
hazards by following safe practices dur-
ing painting, such as maintaining good
flow of fresh air through the paint area
and by following these procedures:
• Use only grounded outlets and elec-
trically conductive hoses.
• Ground all containers and collection
systems.
• When spraying into a container or
collection system, ground gun
against a metal part.
• If you feel a static discharge or other
electrical sparking, stop paint opera-
tions immediately and disconnect all
electrical equipment to the paint
area.
• Keep the area clean and policed of
rags, paint or solvent containers and
other flammables.
• Do not work around open flames,
including pilot lights. Remember
many solvents are heavier than air
and can travel some distance along
the ground.
• Do not smoke in the area.
• Do not operate light switches or gas
powered engines in the area.
• Keep a good supply of fresh air
moving through the area.
TOXIC FLUIDS OR
VAPORS HAZARD
Paints, coatings and solvents may con-
tain toxins and carcinogens. They are
potentially dangerous if absorbed
through the skin or if the vapors are
inhaled. Follow all standard safety pro-
cedures.
• Wear proper protective eyewear and
clothing. Use a respirator.
• Use proper respirator filter for the
paint, coating or solvent in use.
• Change filters frequently as recommend-
ed by the manufacturer.
• Check respirator frequently for
proper fit and keep it clean.
• Check respirator for wear or
cracking.
• Wash skin exposed to fluids imme-
diately with soap and water. Get
medical attention for broken skin
exposed to paint and solvents.
• Know the contents of the paints
and solvents. Read the MSDS and
container labels. Follow the
indicated precautions.
• Store and dispose of hazardous
chemicals and wastes according to
law and regulations.
HIGH PRESSURE
INJECTION HAZARDS
The MACH 2A Spray Gun can pressur-
ize fluids up to 1,000 psi which is suffi-
cient to penetrate skin.
• Do not point the gun at anyone or at
equipment.
• Keep hands and other body parts
away from the spray tip.
• Check all connections for tightness
before starting.
• Check hoses and fittings daily.
Replace damaged or worn equip-
ment. Do not attempt to repair hose
fittings.
• Do not ignore leaks in hoses, or
other equipment and do not attempt
temporary repairs, such as wrapping
a rag around a leak. Replace broken
pieces immediately.
• Follow pressure relief procedures
when ever working on equipment
and as otherwise indicated by good
practice.

SET-UP INSTRUCTIONS
Numbers in parentheses refer to individ-
ual items shown in the “exploded” draw-
ing on page 6.
1. Connect high-pressure airless fluid
hose to the gun fluid inlet (44) and
tighten securely.
2. Connect air hoses to the gun’s double
male nipples (45 & 46) and tighten
both securely.
3. Set regulators to provide the gun with
approximately 40 PSI inlet atomizing
air pressure, 60 PSI cylinder air pres-
sure and about 200 PSI fluid pres-
sure.
4. Rotate the control spindle (16) fully
counterclockwise to obtain maximum
fan pattern width. Remove the retain-
ing ring (1), air cap (2) and spray tip
assembly (3) and aim the gun toward
a container. With cylinder air on, start
fluid pump slowly until fluid flows
steadily from the gun.
5. Shut off the cylinder air to stop the
fluid flow. Replace the spray tip
assembly, air cap and retaining ring.
6. With the fan control air shut off,
adjust fluid pressure until the spray
pattern changes from a pattern with
“tails” to a correctly atomized pat-
tern.
7. Lower fluid pressure until the pattern
with “tails” reappears.
8. Turn on the fan control air. Slowly
increase atomizing air inlet pressure
until the “tails” disappear and the
fluid is well atomized.
If more than about 50 PSI air pressure is
needed to adequately atomize the fluid,
use only about 50 PSI air pressure and
increase the fluid pressure to improve
atomization. Increased fluid pressure
will increase fluid flow as well. If this
increase is unacceptable, use a smaller
fluid tip to reduce fluid flow.
GENERAL SPRAY
INSTRUCTIONS
For maximum efficiency and minimum
overspray, always spray with the lowest
possible fluid/air pressure that will still
deliver an acceptable spray pattern.
Use at least 60 PSI air pressure to oper-
ate the cylinder. Use the shortest possi-
ble air hose between the gun and 3-way
solenoid to improve triggering speed.
Gun-to-target distance will depend on
material choice and atomizing pressure,
but is usually between 6 and 12 inches.
Keep the most recent coating stroke
even and wet to prevent “dry-lap.” Lap
each stroke over the preceding stroke
for a uniform finish.
Since small system leaks can eventually
cause the gun to self-trigger, shut off all
fluid and air lines if the gun is to stand
idle for any length of time.
ADJUSTING THE SPRAY
PATTERN
Adjust the fan spray by using the side
port control assembly. Turning this con-
trol fully clockwise will give a narrow
spray pattern; turning the control coun-
terclockwise will widen the spray into a
fan shape. The fan spray can be posi-
tioned anywhere through 360° by rotat-
ing the air cap assembly relative to the
gun. To reposition the air cap, loosen
the retaining ring slightly and rotate the
air cap to the desired position, then
retighten the retainer ring.
3
SPRAY GUN SET-UP INSTRUCTIONS – SPRAY INSTRUCTIONS
Mounting
Lockscrew
Mounting
Hole (1/2" Dia.)
Side Port
Control Assembly
(Fan Pattern
Control)
Cylinder Air Inlet
1/4 NPS
Atomizing Air Inlet
1/4 NPS
Oil and
Water
Extractor
Atomizing and Fan
Air Combined
3-Way Solenoid
Regulators
TYPICAL HOOK-UP
Fluid Inlet
1/4 NPS
AIR
AIR
GUN
AIR
Cylinder Air
Fluid
“Tails”
Correct
Pattern
Distorted
Pattern
“Hour
Glass”
SPECIFICATIONS
• Maximum Fluid Pressure: 1,000 PSI
• Maximum Air Pressure: 50 PSI
• Gun Body: Forged Aluminum Alloy
• Fluid Path: Stainless Steel and Tungsten
Carbide Parts
• Fluid Shut-off Type: Ball and Seat
• Seat Material: Tungsten Carbide
• Filter Element: Edge Filter (.009" std.)
• Gun Weight: 23.0 Ounces (with filter)

ADJUSTMENTS
4
ADJUSTING THE MATERIAL
VALVE ASSEMBLY
Numbers in parentheses refer to individ-
ual items shown in the “exploded” draw-
ing on page 6.
1. To adjust the material valve assembly
(30), remove end cap (38) and 2
springs (36, 37).
2. Make sure piston (26) is pushed into
gun body (13) as far as it will go.
3. Loosen wire and ball assembly (31)
by unscrewing wire chuck (35) from
needle body (34).
4. Push in needle body (34) until it is
up against the piston (28), then pull
needle body back out approx. 1/32"
(see drawing below) to provide clear-
ance between needle body and piston.
5. Being sure not to overtighten, tighten
wire chuck (35) to needle body (34).
This locks the entire material valve
assembly in place.
6. Replace the springs and end cap.
TO CHANGE FROM COMBINED
FAN AND ATOMIZING AIR TO
SEPARATE AND ATOMIZING AIR
1. Unscrew end cap (38) and remove
springs (36 & 37) and material valve
assembly (30) from gun rear.
2. Remove piston (28) by injecting low
pressure air into cylinder air port (A).
3. Remove plug (20-5692) from cylinder
bore (B) with 5/32" Allen wrench.
4. Insert set screw (20-2141) into posi-
tion.
5. Reinstall plug (20-5692), material
valve assembly, springs and end cap.
6. Remove plug (20-2287) from fan air
port (C).
7. Install fitting (71-28) into port (C).
1/32"
Clearance
Set Screw
(20-2141)
VIEW A
(20-5692)
Side Cut-Away
B
Plug 20-2287
(Remove)
CA40
B
NOTE
If you wish your spray gun to have
separate fan and atomizing air, order
set screw (20-2141) and fitting (71-28)
before following this procedure.
WARNING
Excessive pressure will eject the
piston at high velocity, possibly
resulting in damage to components
or personal injury. Aim the gun rear
in a safe direction and use only low
air pressure to remove the piston.
!

5
CLEANING INSTRUCTIONS
Disassemble and thoroughly clean filter
assembly (40) each time spray gun is
cleaned. Before reassembly, spray gun
should be blown dry and inspected to
make sure debris is not lodged in any of
the air and fluid passages. After reassem-
bly of filter assembly, lightly lubricate
piston assembly (26) to insure smooth
trigger action.
In certain states it is illegal to spray
solvents containing Volatile Organic
Compounds (VOC’s) into the atmos-
phere when cleaning a spray gun. Binks
recommends that you comply with these
air quality laws by following one of the
two methods described below.
1. Use an enclosed clean-up station or
enclosure which will condense and
collect VOC vapors to prevent their
atmospheric release.
2. Use a washer unit.Your gun washer
should completely enclose the spray
gun, filter, nozzles and other parts
during wash, rinse and drain cycles to
prevent the release of VOC vapors
into the atmosphere.
Lubricate all o-rings and moving parts at
reassembly into the gun body.
To further protect the environment,
avoid storing solvents or solvent-soaked
wipes, such as those used for surface
preparation and cleanup, in open or
absorbent containers.
TROUBLESHOOTING
Numbers in parentheses refer to individ-
ual items shown in the “exploded” draw-
ing on page 6.
Uneven spray patterns are usually caused
by a clogged spray tip assembly (3). To
clear the tip, shut off the cylinder air and
remove retainer ring (1), air cap (2) and
tip. Rinse tip in solvents and clean the
orifice with compressed air, then
reassemble.
Intermittent or fluttering spray can be
caused by a clogged filter assembly (40)
or erratic fluid supply. To service the fil-
ter assembly, relieve all fluid pressure
throughout the system, then disassemble
and clean the filter assembly thoroughly.
Always inspect the filter element (42)
when cleaning the filter assembly and
replace damaged elements before
reassembly.
If fluid leaks from the spray tip assembly
when the cylinder air is shut off, remove
and inspect both the carbide seat (6) and
the ball end of the material valve assem-
bly (30). Replace any worn or damaged
parts. Be sure to follow the safety pre-
cautions outlined on page 2.
If fluid leaks past the fluid cartridge
assembly (32), replace the assembly. Be
sure to follow the safety precautions
outlined on page 2.
MAINTENANCE INSTRUCTIONS
Numbers in parentheses refer to individ-
ual items shown in the “exploded” draw-
ing on page 6.
FLUID CARTRIDGE
REPLACEMENT
To remove the fluid cartridge assembly
(32), first remove the material needle
control knob (39), end cap (38) and
springs (36, 37). Loosen wire chuck (35)
from needle body (34). Remove the
retaining ring (1), air cap (2), spray tip
assembly (3), seat retainer (4), carbide
seat (6), and seal assembly (7). Unscrew the
fluid nozzle body (11) with a 1/4" allen
wrench. Loosen fluid cartridge assembly
(32) and pull out the wire and ball
assembly (31) from the front of the gun.
Remove and replace cartridge assembly
(32) and reassemble in reverse order.
PISTON REMOVAL
To remove the piston assembly (26),
unscrew the end cap (38), remove the
two springs (36, 37) and pull out the
entire material valve assembly (30).
Remove the piston assembly by applying
compressed air (about 5 PSI) to the
cylinder air inlet. The air pressure will
cause the piston assembly to pop out.
LUBRICATION
Lubricate the gun by removing the pis-
ton (28) and lubricating the needle return
spring (36) and the bore in which the
piston travels with petroleum jelly.
Periodically lubricate the side port con-
trol assembly (15) with oil.
SPRAY GUN CLEANING & MAINTENANCE INSTRUCTIONS
CAUTION
Never use metal instruments to clean
or scrape fluid or air nozzles. These
parts have been carefully machined
and altering their shape will cause
faulty spray.
!
CAUTION
Never use metal instruments to clean
or scrape fluid or air nozzles. These
parts have been carefully machined
and altering their shape will cause
faulty spray.
!
CAUTION
Never use lubricants containing sili-
cone since these lubricants can cause
finish defects. Binks Gunners Mate
(54-3871) is recommended.
!
WARNING
Be sure to follow all safety precau-
tions described on page 2 before
working on the spray gun. Never
work on the spray gun until fluid
pressure has been relieved through-
out the system and the power or air
supply for the fluid pump has been
disconnected. Always test the
repaired gun for leaks with low
pressure fluid before use.
!
WARNING
Aim the gun rear in a safe direction
and use only low pressure air when
removing the piston assembly.
Removing the piston while under
pressure could result in damage to
components or personal injury.
!
NOTE
Disassemble spray gun and remove
all o-rings (21), (25), (29), (33) & (48)
before immersing gun in or subject-
ing it to a flood-wash of cleaning
solvent. Contact with solvents may
induce o-ring swelling beyond their
specification sizes and cause subse-
quent malfunction of the gun.

6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23 24
26
25 27
28
29
33
34
35
39
38
37
36
53
32
44
45
46
47
48
49
31
50
51
30
52
41
42 43
40
Binks MACH 2A HYDRAULICALLY-ASSISTED AUTOMATIC HVLP SPRAY GUN

PARTS LIST
(Please include part number in order.)
▼Included in Spare parts Kit 54-4405. ▲Part of Item 7.
●Part of Item 3. ♦Part of Item 15.
★Part of Item 30. † Part of Item 40.
■Part of Item 26. ▫Part of Item 13.
‡ Available in Spare Parts Kit 54-3745-5 (quantity of 5).
Air Nozzles Available
93 HA 46-9309 17 PSI Max. Inlet Pressure (10 CFM) - Low Volume
95 HA 46-9509 50 PSI Max. Inlet Pressure (22 CFM) - High Volume
Part Orifice Spray Width
Number Stamp No. (inches) (at 12”)
110-0904 0904 .009 4
110-0908 0908 .009 8
110-0910 0910 .009 10
110-1104 1104 .011 4
110-1108 1108 .011 8
110-1114 1114 .011 14
110-1304 1304 .013 4
110-1306 1306 .013 6
110-1308 1308 .013 8
110-1314 1314 .013 14
110-1504 1504 .015 4
110-1508 1508 .015 8
110-1510 1510 .015 10
110-1514 1514 .015 14
Part Orifice Spray Width
Number Stamp No. (inches) (at 12”)
110-1804 1804 .018 4
110-1808 1808 .018 8
110-1810 1810 .018 10
110-1814 1814 .018 14
110-1820 1820 .018 20
110-2108 2108 .021 8
110-2110 2110 .021 10
110-2114 2114 .021 14
110-2120 2120 .021 20
110-2608 2608 .026 8
110-2610 2610 .026 10
110-2614 2614 .026 14
110-2620 2620 .026 20
110-3610 3610 .036 10
SPRAY TIP ASSEMBLY TABLE – For MACH 2A HVLP SPRAY GUN
7
ITEM PART DESCRIPTION QTY.
NO. NO.
1 54-3531 RETAINING RING ........................ 1
2 AIR NOZZLE (See Chart) .................... 1
3 * SPRAY TIP ASSEMBLY ................ 1
4 54-3745▼●‡ TIP SEAL, Nylon.......................... 1
54-3782 TIP SEAL, Teflon (Optional) .......... 1
5 54-3779 SEAT RETAINER .......................... 1
6 54-3733▼HIGH PRESSURE SEAT ................ 1
7 54-3780▼SEAL ASSEMBLY ........................ 1
8 54-3791▲SMALL RING .............................. 1
9 54-3798▲SEAL GASKET ............................ 1
10 54-3771▲LARGE RING .............................. 1
11 54-3778 FLUID NOZZLE BODY ................ 1
12 54-3543 HEAD INSERT ............................ 1
13 54-3796 MACH 2A GUN BODY ASS’Y. .... 1
14 20-1359 SQ. BOLT 5/16"-18 x 3/4" ................ 1
15 54-3720 SIDE PORT CONTROL ASS’Y....... 1
16 54-3721♦CONTROL SPINDLE .................... 1
17 54-4269♦JAM NUT .................................... 1
18 31-258♦RETAINING PIN .......................... 1
19 31-256♦STUFFING BOX .......................... 1
20 31-259♦INNER WASHER.......................... 3
21 20-3620♦O-RING........................................ 1
22 31-241♦CONTROL SPRING ...................... 1
23 54-3987▫PLUG .......................................... 1
24 54-3988▫PLUG 1/16"-20 NPT ........................ 2
25 20-5286▼O-RING........................................ 1
26 54-3706 PISTON ASSEMBLY .................... 1
27 54-3729■SEAL............................................ 1
28 54-3722■PISTON........................................ 1
ITEM PART DESCRIPTION QTY.
NO. NO.
29 20-4511 O-RING .......................................... 1
30 54-4410▼MATERIAL VALVE ASSEMBLY ........ 1
31 54-4411★▼ WIRE and BALL ASSEMBLY .......... 1
32 54-3635▼★ FLUID CARTRIDGE ASSEMBLY ...... 1
33 20-3515★▼ O-RING .......................................... 1
34 54-3734★▼ NEEDLE BODY .............................. 1
35 54-3524★▼ WIRE CHUCK ................................ 1
36 54-3719 SPRING .......................................... 1
37 54-3707 SPRING .......................................... 1
38 54-3708 END CAP ........................................ 1
39 54-3715 MATERIAL NEEDLE
CONTROL KNOB ........................ 1
40 54-3646 FILTER ASSEMBLY.......................... 1
41 54-3648▼†FILTER BODY SEAL ........................ 1
42 54-1836▼†FILTER ............................................ 1
43 54-3647†FILTER BODY ................................ 1
44 54-3743 FLUID INLET .................................. 1
45 71-28 DOUBLE MALE NIPPLE
1/8" NPT x 1/4" NPS .......................... 1
46 57-13 DOUBLE MALE NIPPLE
1/4" NPT x 1/4" NPS .......................... 1
47 54-3716 AIR VALVE GLAND ASSEMBLY .... 1
48 20-3859▼O-RING .......................................... 1
49 20-2287 PLUG 1/8"-27 NPT.............................. 1
50 54-3918 WRENCH ........................................ 1
51 82-469 GUN BRUSH .................................. 1
52 54-4407 FLUID INLET Recirc. (Optional) .......... 1
53 54-4270 NEEDLE COVER ............................ 1
54 54-4133 GUN BRUSH (Optional) .................... 1

GUN DIMENSIONS
Air Nozzle Test Gauge Assembly
54-3774 95 HA Air Nozzle (50 PSI Max. Inlet Pressure)
54-3622 93 HA Air Nozzle (17 PSI Max. Inlet Pressure)
Atomizing and Inlet Pressures
95HA Air Nozzle
Nozzle Gun Inlet
Atomizing Nozzle Atomizing
Pressure Air Flow Pressure
PSI SCFM PSI
3 11.0 23
4 12.0 27
5 13.5 31
6 15.0 36
7 17.0 40
8 17.5 42
9 18.5 45
10 20.0 50
8
Sales and Service Through a Nationwide Network of Industrial Distributors.
Customer Service in USA / 1-800-992-4657
Technical Support in USA / 1-888-992-4657
195 Internationale Blvd.
Glendale Heights, IL 60139 Part Sheet 2552R-5 Printed in USA 1/01, All Rights Reserved
59-299 GAUGE
7"
WEIGHT:
1.5 lbs.
5"
2"
2552R-5 Revisions: (P7) Parts List: Changed Part No. of Item No. 4 to 54-3745 and added
footnote; changed all Part Nos. and Stamp Nos. in Spray Tip Assembly Table.
IMPORTANT REGULATORY NOTE
Some Regulatory Agencies prohibit the operation of HVLP Spray Guns above 10 psi air nozzle (atomizing)
pressure. Gun users subject to this type of regulation should not exceed 50 psi gun inlet pressure. For fur-
ther information, see General Spray Instructions, page 3. The nozzle test gauge (see below) should be used
to confirm actual nozzle operating pressure.
Some Regulatory Agencies may require that users have this nozzle test gauge on site to verify the gun’s
compliance with current regulations.