Reassembly - Graco 2K Ultra-Lite Series Instructions-Parts List Manual

Reassembly

Air Cylinder Section
1. Lubricate the shaft o-rings (4) and the bearings (5)
with grease supplied in the repair kit. Insert o-rings
into the air cylinder (1) and air cap (11) cavities.
See Fig. 6.
2. Press the bearings (5) flush into the air cylinder
housing and air cap, trapping the o-rings (4).
3. Lubricate and reassemble the piston assembly;
piston (10), o-rings (9), dowel pin (7), nuts (8), and
o-ring (6), and air cylinder shaft (3). Tighten nuts
(8) to 15–20 in-lb (1.7–2.2 NSm). The shafts (3)
should hang with some play to be self-aligning in
the bearing.
4. Lubricate the air cylinder (1) ID with the grease
supplied. Push the piston (10) assembly into the
air cylinder.
5. Insert "C" clip (12). Orient clip opening in front of
air passage way.
6. Lube and assemble an o-ring (16) onto cap (11).
Push cap (11) straight into housing (1).
7. Insert outside "C" clip (12).
8. Orient the air inlet manifold (2) (if used) as shown.
Match the gasket openings to the air ports.
Fluid Section
1. Lubricate the bearings (21), o-rings (16) and cup
seals (20). Put the o-rings (16) on the bearings.
Carefully insert the seals (20) into the bearing
recess, with the lips of the o-rings facing into the
bearing. Be careful not to damage the seal lips.
2. Push the bearings (21) seal end first into the
housing (19). Be sure that the grease holes in the
side of the bearings line up with the grease ports in
the housing (19).
18 309000
Service
3. Holding the bearings (21) in place, push the bear-
ing assembly over the shafts (3).
4. Lubricate the main fluid seals (22) and its cavity in
the housing (26). Carefully press the seals, lip end
first, into the housing.
5. Push the housing (26) and seals (22) over the
shafts (3) and up against the bearing housing.
6. Loosely install the fluid housing screw (23) using
an anti–seize lubricant such as Loctiter 56765. Do
not tighten screws yet.
7. Insert the gaskets (36) and seats (25). The seats
are reversible and can be installed in either direc-
tion.
8. Use Loctite primer N 7649 and Loctite TL242, 243,
or equivalent ("blue" Loctite) when reassembling
the needle (27). Screw in the needle (27) and
tighten it to 15–20 in–lb (1.7–2.2 NSm).
9. Apply air pressure to the CLOSE port, or to the
pneumatic trigger valve if installed. This will align
the shaft, seal, and bearing. Tighten the fluid
housing screws (23) oppositely and evenly to
40–45 in-lbs (4.5–5 NSm).
10. Install the nosepiece (31) with the PTFE o-rings
(14), screws (37), and snuff-back rings (13), if
used. The snuff-back rings have an internal bevel
on one end which faces into the nosepiece. Tight-
en the nosepiece screws to 15–20 in-lbs (1.7–2.2
NSm).
11. Install pin (34) and restrictor (32 or 33) if used.
Restrictor (33) uses an o-ring (35).
12. After rebuilding the valve or replacing the needles
and seats, the cycle the valve 50 times at full air
pressure to "seat" the hardened needles to the
carbide seats.