Graco 2K Ultra-Lite Series Operation manual

Instructions–Parts List
309000M
EN
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
AIR OPERATED, TWO COMPONENT DISPENSE VALVE
2K Ultra-Litet
For use with disposable mixers to dispense a variety of sealants and adhesives. For
professional use only.
3000 psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure
120 psi (0.84 MPa, 8.4 bar) Maximum Air Inlet Pressure
Machine Mount Valves
Part No. 570145, Aluminum Wide Ratio
Part No. 570151, For P-Dose 1/2 G mixers
Part No. 965533, Aluminum Wetted
Part No. 965534, Stainless Steel Wetted
Hand Held Valves with Internal Air Trigger
Part No. 570182, Aluminum Wide Ratio
Part No. 965535, Aluminum Wetted
Part No. 249591, Aluminum Wetted,
Bare Valve Without Outlet Manifold
Part No. 965536, Stainless Steel Wetted
Hand Held Valves with Electric Switch
for Remote Operation
Part No. 965537, Aluminum Wetted
Part No. 965538, Stainless Steel Wetted
Hand Held Valve Shown

2 309000
Table of Contents
Symbols 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Selection 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Switch Valve 8. . . . . . . . . . . . . . . . . . . . . . . .
2K Ultra-Lite Disposable Mixer Dispenser Valve 9.
Installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use the Valve Trigger Safety 10. . . . . . . . .
System Setup 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid and Air Connections 11. . . . . . . . . . . . . . . . . . .
Inlet Check Valves 11. . . . . . . . . . . . . . . . . . . . . . . . .
Balancing the System 11. . . . . . . . . . . . . . . . . . . . . .
Selecting Hoses 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
System Start-up 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Mixer Selection 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Amount of Snuff Back 12. . . . . . . . . . . .
Operation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 13. . . . . . . . . . . . . . . . . .
Electric Switch Hand Held Valve 13. . . . . . . . . . . . .
Machine Mount Valve 13. . . . . . . . . . . . . . . . . . . . . .
Air Switch Hand Held Valve 14. . . . . . . . . . . . . . . . .
Ratio Checking 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Shut-down 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance 15. . . . . . . . . . . . . . . . . .
Troubleshooting 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model 570145, 570151, 570182,
965533, 965535, 965537, 249591 23. . . . . . . . . . . .
Model 965534, 965536, 965538 24. . . . . . . . . . . . .
Model 570182, 965535, 965536, 249591 26. . . . . .
Model 965537 and 965538 26. . . . . . . . . . . . . . . . . .
Accessories 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plastic Tube Fittings to Connect Air Signals 27. . .
Inlet Check Valves (3000 psi working pressure) 27
Catalyst Injectors 27. . . . . . . . . . . . . . . . . . . . . . . . . .
Plastic Tubing for Air Signal Lines 27. . . . . . . . . . . .
Air Signal Accessories 27. . . . . . . . . . . . . . . . . . . . . .
Solenoids 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposable Mixers 28. . . . . . . . . . . . . . . . . . . . . . . . .
Mixer Jackets 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retaining Nuts 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Nose Piece Restrictors 28. . . . . . . . .
Optional Main Fluid Needle Packings (22) 29. . . . .
Application Kits 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conversion Kits 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 32. . . . . . . . . . . . . . . . . . . . .
Graco Information 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3309000
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
Warnings
WARNING
HAZARD OF USING FLUIDS CONTAINING HALOGENATED HYDROCARBONS
Never use 1, 1, 1-trichloroethane, methylene chloride, and other halogenated hydrocarbon solvents of fluids
containing such solvents in this equipment. Such use could result in a serious chemical reaction, with the possi-
bility of explosion, which could cause death, serious bodily injury and/or substantial property damage.
Consult your fluid suppliers to ensure that the fluids being used are compatible with aluminum and zinc parts.
WARNING
PLURAL COMPONENT MATERIALS HAZARD
Graco Inc. does not manufacture or supply any of the reactive chemical components that are used in this equip-
ment and is not responsible for their effects. Because of the vast number of chemicals that could be used and
their varying chemical reactions, the buyer and user of this equipment should determine all facts relating to the
materials used, including any of the potential hazards involved. Particular inquiry and investigation should be
made into potential dangers relating to toxic fumes, fires, explosions, reaction times and exposure of human
beings to the individual components or their resultant mixtures.
Graco assumes no responsibility for loss, damage, expense or claims for bodily injury or property damage, direct
or consequential, arising from use of such chemical components.

4 309000
WARNING
SKIN INJECTION HAZARD
Spray from the valve, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical treatment.
DDo not point the valve at anyone or at any part of the body.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DBe sure the valve trigger safety operates before dispensing.
DLock the valve trigger safety when you stop dispensing.
DIf the nozzle clogs while dispensing, fully release the trigger immediately.
DFollow the Pressure Relief Procedure on page 13 whenever you: are instructed to relieve pres-
sure; stop dispensing; clean, check, or service the equipment; and install or clean the nozzle.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
DUse only Graco approved hoses. Do not remove any spring guard that is used to help protect the
hose from rupture caused by kinks or bends near the couplings.
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure stated on the equipment or in the Technical Data
for your equipment. Do not exceed the maximum working pressure of the lowest rated component
in your system.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DDo not use hoses to pull equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 180_F (82_C) or below –40_F (–40_C).
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
DNever use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in this equipment. Such use could result in a serious chemical
reaction, with the possibility of explosion, which could cause death, serious injury, and/or substan-
tial property damage.

5309000
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
DGround the equipment and the object being sprayed. Refer to Grounding on page 10.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DExtinguish all open flames or pilot lights in the dispense area.
DDo not smoke in the dispense area.
DDo not turn on or off any light switch in the dispense area while operating or if fumes are present.
DDo not operate a gasoline engine in the dispense area.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

6 309000
Typical Installation
A
F
C
E
B
D
Shown on a Graco 8900 proportioning system
J
H
G
L
M
I
N
P
K
O
Q
KEY
A2K Ultra-Lite valve
B8900 Proportioner
C“A” side pump
D“B” side pump
EBoom kit
FDisposable mixer
G1/8 in. npt (f) air to close
H1/4 in. npt (f) air to open
I1/4 in. npt (f) “A” fluid inlet (3 places)
J1/4 in. npt (f) “B” fluid inlet (3 places)
LZirk grease fitting
MFlush grease fitting
N4-way trigger valve or electric switch
OTrigger lock
P1/8 in. npt(f) hand gun air inlet.
NOTE: The electric switch model has 1/8
in. npt(f) ports “OPEN” on the side and
“CLOSE” on the other side.
QThere is a 1/8 in. npt(f) port on air man-
ifold which can be used to send an “ON”
signal back to a pump pilot or control.

7309000
Features
Model Selection
The following table provides a summary of the 2K Ultra-Litetdispense valves that are described in this manual.
Type Description
Wetted parts Aluminum wetted 2K-UL valves are lightweight and inexpensive, but have less chemical
compatibility than stainless steel wetted valves.
Hand held valves with
internal air trigger
The internal air trigger controls the air piston that operates the 2K-UL valve. A pilot port
can be used to control a pump motor.
Hand held valve with
electric switch
The switch signals the customer’s controller to open and close the ports on the 2K-UL
valve using a remote 4-way air control valve which is not included.
Hand held, wide ratio
valves
The wide ratio 2K-UL valve has two features: a center inject nozzle in the nosepiece and
a “shower head” tip. The features are helpful in applications when the mix ratio volume is
greater than 10:1, specifically when minor volume is a lower viscosity than major volume.
Frequent cleaning intervals are required to maintain the center inject nozzle and shower
head tip.

8 309000
Features
Electric Switch Valve
Figure 2 shows the electric switch valve and provides useful installation information.
Fig. 2
SOLDER TO TERMINALS
IN CABLE CONNECTOR
AS SHOWN
NORMALLY OPEN
MOMENTARY
CONTACT SWITCH
DOT INDICATES
GROUND CONNECTION
NOTE:
THIS VALVE IS ACTIVATED BY A REMOTE
SOLENOID. THE TRIGGER ONLY ACTIVATES
THE ELECTRICAL SWITCH IN THE HANDLE.
BRING AN “OPEN” AIR SIGNAL TO THE 1/8 in.
NPT (F) PORT ON THIS SIDE OF THE VALVE,
AND A “CLOSE” SIGNAL TO THE PORT ON
THE OPPOSITE SIDE.

9309000
Features
2K Ultra-Lite Disposable Mixer Dispense Valve
Figure 3 shows the features of the 2K Ultra-Lite valve, which is used for dispensing a wide variety of two compo-
nent sealant and adhesives through disposable static mixers.
Fig. 3
FOUR CONTROL CONFIGURATIONS
1. 1/8 in. NPT (F) PORTED MANIFOLD BLOCK.
2. DIRECT SOLENOID MOUNT WITH SPEED CONTROL.
3. HANDLE KIT WITH 4-WAY AIR VALVE.
4. HANDLE KIT WITH ELECTRIC SWITCH.
ACCESSORY FLOW
CONTROL FITTINGS
TO ADJUST OPEN
AND CLOSE SPEED.
SHAFTS ARE FREE
TO ALIGN
CHOICE OF ALUMINUM
OR STAINLESS WETTED
HOUSINGS.
SNUFF BACK INSERTS ARE
REMOVABLE FOR LOW FLOW OR
WIDE RATIO APPLICATIONS.
HELPS ELIMINATE CROSSOVER.
REPLACEABLE NYLON
BEARING
DIVORCED AIR SECTION
WITH MATERIAL DAM.
HARD CHROMED
SST SHAFTS
URETHANE U-CUP
SECONDARY SEALS.
SELF CENTERING
PLASTIC BEARING
PROVEN PRIMARY SEALS
HARDENED STAINLESS
STEEL NEEDLES.
REVERSIBLE CARBIDE
SEAT FOR SEVERE DUTY
SIMPLE INEXPENSIVE RESTRICTORS
TO BALANCE FLOW OR CENTER
INJECTION NOSE PIECE MODEL FOR
WIDE RATIO APPLICATIONS.

10 309000
Installation
NOTES:
DReference numbers and letters in parentheses in
the text refer to the callouts in the figures and
drawings.
DAccessories are available from your Graco repres-
entative. If you supply your own accessories, be
sure they are adequately sized and pressure-rated
to meet the system’s requirements.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
To reduce the risk of fire, explosion, and
serious injury, proper electrical ground-
ing of every part of your system is es-
sential. Read the warning section Fire
and Explosion Hazard on page 5, and
follow the grounding instructions below.
The following grounding instructions are minimum
requirements for a basic dispensing system. Your
system may include other equipment or objects which
must be grounded. Check your local electrical code for
detailed grounding instructions for your area and type
of equipment. Your system must be connected to a
true-earth ground.
DPump: ground the pump by connecting ground wire
and clamp as described in your separate pump
instruction manual.
DAir compressors and hydraulic power supplies:
ground the equipment according to the manufactur-
er’s recommendations.
DFluid hoses: use only grounded fluid hoses with a
maximum of 500 feet (150 m) combined hose
length to ensure grounding continuity. Check the
electrical resistance of your fluid hoses at least
once a week. If your hose does not have a tag on it
which specifies the maximum electrical resistance,
contact the hose supplier or manufacturer for the
maximum electrical resistance limits, replace the
hose immediately.
DDispensing valve: ground the valve by connecting it
to a properly grounded fluid hose and pump.
DFluid supply container: ground according to your
local code.
DFlammable liquids in the dispense area: must be in
approved, grounded containers. Do not store more
than the quantity needed for one shift.
DAll solvent pails used when flushing: ground ac-
cording to local code. Use only metal pails, which
are conductive. Do not place the pail on a non-con-
ductive surface, such as paper or cardboard, which
interrupts the grounding continuity.
DTo maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the valve
firmly to the side of a grounded metal pail, then
trigger the valve.
How to Use the Valve Trigger Safety
WARNING
To prevent accidental triggering of the
gun and reduce the risk of a serious inju-
ry, including fluid injection or splashing in
the eyes or on the skin, lock the gun trigger safety
when you stop dispensing.
SKIN INJECTION HAZARD
1. If you are using one of the hand-held versions of
the valve, lock the valve trigger safety by turning
the latch to a right angle with the gun body. See
Fig. 4.
2. To unlock the valve trigger safety, push the latch
out and turn it parallel with the gun body.
Fig. 4 8459
A
Locked Unlocked