Carlisle Binks 102-2400 FRP Service Manual Download Page 14

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77-2520-R15 (5/2019)

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6. Put the new catalyst seat into the hole of the gun head that

the catalyst needle assembly came out of. The small end
of the catalyst seat must go in first. The seat should drop
down into the gun head.

7. The seat now needs to be pressed into place such that a

tight fit is created between the resin seat and the walls of
the gun head that retain it. Use a 1/4" diameter dowel to
press the seat tight. Be careful not to scratch the walls of
the gun head. A drill press or arbor press is best for this
operation.

8. Reassemble in reverse order.

REPLACING RESIN SEAT

1. Remove air/catalyst cap retainer ring (1), air/catalyst cap

(2), the spray tip assembly (5), and the two o-rings
(7 & 8) from the gun head.

2. Pull the trigger (62) to unseat needle from the seat (10)

and remove head insert (72) with a 13/16" wrench.
Remove seal (73) and replace with new seal.

3. Place head insert on a flat clean surface with the back of

the hex of the head insert against the surface. This will
require a hole or recess in the surface such that the head
Insert does not rest against anything. A 9/16" diameter
hole with a minimum depth of one inch would accommo-
date this. Align 13/64" dowel pin (70) (available in Repair
Kit 106-1171) with the center of the hole of the head
insert. Move the dowel pin straight down until it seats
against the resin seat (10). This will be about 1/2" from
the top surface to the head insert. Press the seat out. This
is most easily done on a drill press or arbor press.

4. Now place the front of the head insert with grooves

against a flat clean surface.

5. Put the new resin seat into the tapered hole of the head

insert. The small end of the resin seat must go in first. The
seat now needs to be pressed in place such that a tight fit
is created between the resin seat and the walls of the head
insert that retain it. Use 3/8" diameter dowel pin (71)
(available in Repair Kit 106-1171) to press the seat
tight. A drill press or arbor press is best for this operation.

6. Reassemble in reverse order.

REPLACING THE RESIN NEEDLE PACKING

1. Remove the button head screw (65) that retains the guard

assembly (64) by using a 3/16" hex key; remove the guard
assembly.

2. Using two standard screwdrivers, remove the trigger stud

(60), the trigger screw (61), the trigger (62), and the chop-
per trigger assembly (54).

3. Using 3/8" wrench or socket, remove the head retainer (51).
4. Slide the gun head (9) as far forward as it will go with your

hands. Do not use excessive force.

5. Unscrew the resin packing nut (15) with a 3/8" wrench and

pull the resin needle assembly (11) straight back until it
comes out of the gun head. Be sure to pull the needle out
without bending it up or down or side to side as this will
cause the needle to bend, thus ruining the needle.

6. Clean the needle assembly so that you may be able to

clearly identify the packing (13).

7. The packing is the only non-metal piece of the needle

assembly and is white in color. Note its location and orien-
tation on the wire of the needle. Cut the worn packing away
with a sharp knife being sure not to scratch or deform any
nearby parts.

8. Carefully spread the new packing apart, about 3/64" at the

edge (this can be done easily with an X-acto type knife) and
press the packing onto the wire of the needle assembly in
the same location and orientation as noted in step 7. Gently
squeeze the packing closed with fingers.

9. Slide the packing forward and back with your fingers to

assure a proper fit onto the wire.

10.Reassemble in reverse order.

REPLACING THE RESIN NEEDLE ASSEMBLY

1. Repeat steps 1 thru 5 from section

“Replacing the Resin

Needle Packing” above.

2. Replace worn needle assembly with new needle assembly.
3. Reassemble in reverse order.

REPLACING THE CATALYST NEEDLE ASSEMBLY

1. Repeat steps 1 and 2 from the section

“Replacing the

Catalyst Needle Packing” above.