Graco Viscount I Plus Operation manual

Plus

INSTRUCTIONS–P ARTS LIST 308–330
Rev. A
Viscount I Hydraulic Motor
1500 psi (105 bar) Maximum Hydraulic Input Pressure
Part No. 236–417, Series A
US and Foreign Patents Pending
Table of Contents
Warnings 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 7–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 15–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 20. . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1994, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE

 
W ARNINGS
High Pressure Spray Can Cause Serious Injury . For Professional Use Only.
Observe All W arnings. Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
The hydraulic motor and pump can generate high fluid pres -
sure. Spray from leaks or ruptured components can inject
fluid through your skin and into your body and cause ex -
tremely serious bodily injury , including the need for amputa -
tion. Also, fluid injected or splashed into the eyes or on the
skin can cause severe damage.
Never point the spray gun/dispense valve at anyone or at any
part of the body . Never put hand or fingers over the spray
tip/nozzle.
Always have the tip guard in place on the spray gun when
spraying.
Always follow the Pressure Relief Procedure, right, before
cleaning or removing the tip/nozzle or servicing any system
equipment.
Never try to stop or deflect leaks with your hand or body .
Be sure all equipment safety devices are operating properly
before each use.
Medical Alert – Airless Spray W ounds
If any fluid appears to penetrate your skin, get emergency
medical care at once. Do not treat as a simple cut. T ell the
doctor exactly what fluid was injected.
NOTE TO PHYSICIAN: Injection into the skin is a traumatic
injury. It is important to treat the injury surgically as soon
as possible. Do not delay treatment to research toxicity . T ox-
icity is a concern with some exotic coatings injected directly
into the blood stream. Consultation with a plastic surgeon or
reconstructive hand surgeon may be advisable.
Spray Gun/Dispensing V alve Safety Devices
Be sure all spray gun/dispensing valve safety devices are
operating properly before each use. Do not remove or modify
any part of the gun/valve; this can cause a malfunction and
result in serious bodily injury .
Safety Latch
Whenever you stop spraying/dispensing, even for a moment,
always set the spray gun/dispensing valve safety latch in the
closed or “safe” position, making the gun/valve inoperative.
Failure to set the safety latch can result in accidental trigger
-
ing of the gun/valve.
Trigger Guard (if so equipped)
Never operate the spray gun/dispensing valve with the trigger
guard removed. This guard helps prevent the gun/valve from
triggering accidentally if it is dropped or bumped.
Diffuser (only on spray guns)
The spray gun dif fuser breaks up spray and reduces the risk
of fluid injection when the tip is not installed. Check the dif -
fuser operation regularly . Follow the Pressure Relief Proce -
dure
, below , then remove the spray tip. Aim the spray gun
into a grounded metal pail, holding the spray gun firmly to the
pail. Using the lowest possible pressure, trigger the spray
gun. If the fluid emitted is not dif fused into an irregular stream,
replace the dif fuser immediately .
Tip Guard (only on spray guns)
Always have the tip guard in place on the spray gun while
spraying. The tip guard alerts you to the fluid injection hazard
and helps reduce, but does not prevent, the risk of acciden -
tally placing your fingers or any part of your body close to the
spray tip.
Spray T ip/Nozzle Safety
Use extreme caution when cleaning or changing spray tips/
nozzles. If the spray tip/nozzle clogs while spraying/dispens -
ing, engage the safety latch immediately . Always follow the
Pressure Relief Procedure
and then remove the spray tip/
nozzle to clean it.
Never wipe of f build-up around the spray tip/nozzle until pres -
sure is fully relieved and the safety latch is engaged.
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including fluid injec -
tion, injury from moving parts, and splashing in the eyes or on
the skin, always follow this procedure whenever you shut of f
the pump, when checking or servicing any part of the spray/
dispense system, when installing, cleaning or changing tips/
nozzles, and whenever you stop spraying/dispensing.
1. Engage the spray gun/dispensing valve safety latch.
2. Close the supply line shutof f valve(s) first, then the return
line shutof f valve(s). In a multi-pump system, do this at
each pump to isolate the pumps.
3. Disengage the gun/valve safety latch.
4. Hold a metal part of the gun/valve firmly to the side of a
grounded metal pail, and trigger the gun/valve to relieve
pressure.
5.
Engage the gun/valve safety latch.
6. Open the pump outlet drain valve(s), having a container
ready to catch the drainage.
7. Leave the drain valve(s) open until you are ready to
spray/dispense again.
If you suspect that the tip/nozzle or hose is completely
clogged, or that pressure has not been fully relieved after
following the steps above, very slowly loosen the tip guard
retaining nut or hose end coupling to relieve pressure gradu -
ally
, then loosen completely . Now clear the obstruction.

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EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray/dispense equipment or accessories,
such as overpressurizing, modifying parts, using incompatible
chemicals and fluids, or using worn or damaged parts, can
cause them to rupture and result in fluid injection or other
serious bodily injury , fire, explosion or property damage.
Never alter or modify any part of this equipment; doing so
could cause it to malfunction.
Check all spray/dispense equipment regularly and repair or
replace worn or damaged parts immediately .
Always read and follow the fluid and solvent manufacturer ’s
recommendations regarding the use of protective eyewear ,
clothing and equipment, including respirators.
Fluid Compatibility
Be sure that all fluids and solvents used are chemically com -
patible with the wetted parts shown in the T echnical Data
section of the separate displacement pump manual. Always
read the fluid and solvent manufacturer ’ s literature before
using them in your system.
System Pressure
The Maximum Hydraulic Input Pressure for this motor is 1500
psi (105 bar) . The Maximum Hydraulic Return Line Pressure
is 20 psi (1.4 bar) . Never exceed these pressures. Consult
your separate pump instruction manual for the maximum
working pressure of the complete pump.
Be sure that all accessories and components added to the
system are rated to withstand the maximum hydraulic input
pressure and maximum fluid working pressure of the pump.
FIRE OR EXPLOSION HAZARD
Static electricity is created by the high velocity flow of fluid
through the motor , pump and hose. If the pump is not prop -
erly grounded, sparking may occur , and the system may be -
come hazardous. Sparks from any source can ignite fumes
from solvents and the fluid being dispensed, dust particles
and other flammable substances, and can cause a fire or
explosion and serious bodily injury and property damage. Do
not smoke, and do not plug in or unplug any power supply
cords in the spray area when there is any chance of igniting
vapors still in the air .
If you experience any static sparking or even a slight shock
while using this equipment, stop spraying/dispensing im -
mediately
. Do not use the system again until the problem
has been identified and corrected.
Grounding
T o reduce the risk of static sparking, ground the pump, object
being sprayed, and all other spray/dispensing equipment
used or located in the spray/dispensing area. Check your
local electrical code for detailed grounding instructions for
your area and type of equipment. Be sure to ground all of this
spray/dispensing equipment:
1. Pump: use ground wire and clamp as shown in Fig. 1.
2. Hydraulic Hoses and Fluid Outlet Hoses: use only elec -
trically conductive hoses. Refer also to HOSE SAFETY
on page 4.
3. Hydraulic Power Supply: follow manufacturer ’s recom-
mendations.
4.
Spray gun/dispensing valve: obtain grounding through
connection to a properly grounded fluid hose and pump.
5. Fluid supply container: according to local code.
6. Object being sprayed: according to local code.
7. Any pails used when flushing: Use only metal, grounded
pails when flushing. Make firm metal-to-metal contact
between a metal part of the gun/valve and the pail. Use
the lowest possible pressure.
8. T o maintain grounding continuity when flushing or reliev -
ing pressure, always hold a metal part of the gun/valve
firmly to the side of a metal pail , and then open the gun/
valve.
T o ground the pump, loosen the grounding lug locknut (W)
and washer (X). Insert one end of a 12 ga (1.5 mm
@ ) mini -
mum ground wire (Y) into the slot in lug (Z) and tighten the
locknut securely . Connect the other end of the wire to a true
earth ground. See Accessories for an available ground wire.
Fig. 1
W
XZ
Y
Flushing Safety
Before flushing, be sure the entire system and flushing pails
are properly grounded. Refer to Grounding , at left. Follow
the Pressure Relief Procedure on page 2, and remove the
tip/nozzle from the gun/valve. Always use the lowest possible
fluid pressure, and maintain firm metal-to-metal contact be -
tween the gun/valve and the pail during flushing to reduce the
risk of fluid injection injury , static sparking and splashing.
Hydraulic Oil T emperature
If hydraulic oil becomes too hot, it can reach its flash point
and cause a fire. Operating at too high an oil temperature can
also cause faster motor seal wear and leakage. The recom -
mended hydraulic oil operating temperature is 80–1 15_F
(27–45_
C). If the oil temperature approaches 130 _ F (54 _C),
shut off the motor and check the hydraulic oil supply cooling
system, filters, etc. Clean or repair as needed.
Always use Graco-approved Hydraulic Oil or equivalent (see
Accessories ). Do not substitute a lower grade oil or one with
a lower flash point.

4 308-330
HOSE SAFETY
High pressure fluid in the hydraulic hoses and pump fluid
outlet hoses can be very dangerous. If a hose develops a
leak, split or rupture due to any kind of wear , damage or mis -
use, the high pressure spray emitted from it can cause a fluid
injection injury or other serious bodily injury or property dam -
age.
All fluid hoses must have spring guards on both ends!
The spring guards help protect the hose from kinks or bends
at or close to the coupling which can result in hose rupture.
T ighten all fluid connections securely before each use. High
pressure fluid can dislodge a loose coupling or allow high
pressure spray to be emitted from the coupling.
Never use a damaged hose. Before each use, check the en -
tire hose for cuts, leaks, abrasion, bulging cover , or damage
or movement of the hose couplings. If any of these conditions
exist, replace the hose immediately
. Do not recouple high
pressure hose. Never use tape or any device to try to mend
the hoses; it cannot contain the high pressure fluid.
Handle and route hoses carefully . Do not pull on hoses to
move equipment. Do not use fluids or solvents which are not
compatible with the inner tube and cover of the hose. Do not
expose Graco hose to temperatures above 180  F (82  C) or
below –40  F (–40  C).
Hose Grounding Continuity
Proper hose grounding continuity is essential to maintaining a
grounded spray/dispensing system. Check the electrical re -
sistance of your hydraulic and 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 resistance limits. Use a
resistance meter in the appropriate range for your hose to
check the resistance. If the resistance exceeds the recom-
mended limits, replace it immediately . An ungrounded or
poorly grounded hose can make your system hazardous.
Also, read FIRE OR EXPLOSION HAZARD , on page 3.
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers or other
body parts. The motor extension rod extends below the motor
base during operation, and can pinch or amputate fingers
caught between the rod and the base. Keep clear of moving
parts when starting or operating the pump. Follow the Pres-
sure Relief Procedure on page 2 before checking or serv -
icing the pump to prevent it from starting accidentally .
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These stan -
dards––particularly the General Standards, Part 1910––should be consulted.
TERMS
Be sure you read and understand each of these terms be -
fore reading the rest of the manual.
WARNING: Alerts user to avoid or correct conditions which
could cause bodily injury .
CAUTION:
Alerts user to avoid or correct conditions which
could cause damage to or destruction of equipment.
NOTE: Gives additional information or helpful hints.

5308-330
Installation
General
Connect the hydraulic motor (A) to the displacement
pump (B) as explained in your separate pump manual.
See Fig. 2.
Mount the pump to suit the type of installation planned.
A motor mounting plate (P) is available; see Accesso-
ries
on page 18 to order . For detailed installation in -
formation, contact your Graco distributor or Graco
T echnical Assistance (see back cover).
Be sure that your power supply is equipped with a suc -
tion filter to the hydraulic pump and a system return
line filter of 10 micron size.
CAUTION
Keep the hydraulic system clean
T o reduce the risk of damaging the hydraulic power
supply and motor
, blow out all hydraulic lines with
air , flush thoroughly with solvent, and then blow out
with air again before connecting the lines to the
hydraulic motor .
Always plug the hydraulic inlets, outlets and lines
when disconnecting them for any reason to avoid
introducing dirt and other contaminants into the
system.
Carefully follow the manufacturer ’ s recommenda -
tions on reservoir and filter cleaning, and periodic
changes of hydraulic fluid. The maximum water
content of the hydraulic oil is 1 percent.
Install the Drain Bottle
1. Push the drain hose (1 13) securely onto the
barbed adapter (1 12). See Fig. 2.
2. Position the holder (1 15) on a pump tie rod (C) and
secure with the hose clamp (1 16). Place the drain
bottle (114) in the holder .
3.
Place the drain hose (1 13) in the drain bottle so it
hangs well down inside the bottle. Adjust the posi -
tion of the holder , if necessary .
03139
Fig. 2
113112
115
114
116
A
Viscount Motor
Shown Mounted
on a Mid-Range
High-Flo
 Pump
C
B
P
Grounding
WARNING
For your safety , read the FIRE AND EXPLOSION
HAZARD section on page 3 and ground the entire
system as explained there.

6 308-330
Operation
Startup
Before each use, check the hydraulic fluid level and
add fluid as necessary to fill the lines.
T o start the pump, turn on the hydraulic power supply .
Open the return line shutof f valve first , then open the
supply line shutof f valve.
WARNING
Hydraulic Oil T emperature
If hydraulic oil becomes too hot, it can reach its
flash point and cause a fire. Operating at too high
an oil temperature can also cause faster motor seal
wear and leakage. The recommended hydraulic oil
operating temperature is 80–1 15F (27–45 C). If
the oil temperature approaches 130 F (54 C), shut
of f the motor and check the hydraulic oil supply
cooling system, filters, etc. Clean or repair as
needed.
Always use Graco-approved Hydraulic Oil or equiv -
alent (see Accessories ). Do not substitute a lower
grade oil or one with a lower flash point.
The equivalent is a premium, ISO grade 46
petroleum-based hydraulic oil containing rust and
oxidation inhibitors and anti-wear agents. Before
using any other type of oil in this equipment,
contact Graco T echnical Assistance,
1–800–543–0339. Unauthorized use of lesser
grade oil or substitutes will void the warranty .
Shutdown & Care
Follow the Pressure Relief Procedure W arning be-
low.
Always shut of f the supply line shutof f valve first , and
then the return line shutof f valve. This is to prevent
overpressurizing the motor or its seals. When starting
the hydraulic system, open the return line shutof
f valve
first.
WARNING
Pressure Relief Procedure
T o reduce the risk of serious bodily injury , including
fluid injection, injury from moving parts, and splash -
ing in the eyes or on the skin, always follow this
procedure whenever you shut of f the pump, when
checking or servicing any part of the spray/dis -
pense system, when installing, cleaning or chang -
ing tips/nozzles, and whenever you stop spraying/
dispensing.
1.
Engage the spray gun/dispensing valve safety
latch.
2.
Close the supply line shutof f valve(s) first, then
the return line shutof
f valve(s). In a multi-pump
system, do this at each pump to isolate the
pumps.
3.
Disengage the gun/valve safety latch.
4. Hold a metal part of the gun/valve firmly to the
side of a grounded metal pail, and trigger the
gun/valve to relieve pressure.
5. Engage the gun/valve safety latch.
6. Open the pump outlet drain valve(s), having a
container ready to catch the drainage.
7. Leave the drain valve(s) open until you are
ready to spray/dispense again.
If you suspect that the tip/nozzle or hose is com -
pletely clogged, or that pressure has not been fully
relieved after following the steps above, very slow -
ly
loosen the tip guard retaining nut or hose end
coupling to relieve pressure gradually , then loosen
completely . Now clear the obstruction.

7308-330
Troubleshooting
Problem Cause Solution
Reciprocator stops running. W orn valve or valve balls (3);
broken valve spring (18).
Repair valve. See page 10.
Broken trip rod (17), spring (12) or
retainers (11).
Replace parts. See page 10.
Poor performance or reduced ef fi-
ciency.
W orn piston seals (5, 6, 7). Replace seals. See page 10.
Oil leaking down extension rod. Worn o-ring (1 17) in oil deflector . Replace o-ring. See page 8.
Oil leaking around cylinder . W orn cylinder o-rings (2). Replace o-rings. See page 10.
Loose tie rods (37). T ighten nuts (106). See page 8.
Oil leaking around inlet or return
tube fittings.
Loose fittings or worn fitting
o-rings.
T ighten or replace fittings (31, 34,
38). See page 10.
Excessive oil in drain bottle, or
bottle needs frequent emptying.
W orn seals in bottom cylinder cap. Replace seals (2, 15, 14 and 49).
See page 10.
Service
Tools Required
DSet of allen wrenches
D Set of socket or box wrenches
D Adjustable wrench
DT orque wrench
D Spanner wrench
D O-ring pick
D 10–24 unc–2b tap
DVise
D
Shallow metal or plastic pan (approx. 12 x 20 in.)
D Repair T ool 189–305 (see page 18)
D Thread lubricant
D Lithium-base grease
D Fresh Loctite r 242 thread sealant and Loctite r
Primer T or Perma-Loc r 115 thread sealant and
Perma-Bondr Surface Conditioner I
D Chlorinated solvent
Disconnecting the Hydraulic Motor
WARNING
To reduce the risk of serious bodily injury , including
fluid injection, injury from moving parts, and splash -
ing in the eyes or on the skin, always follow the
Pressure Relief Procedure on page 6 whenever
you shut of f the pump, when checking or servicing
any part of the spray/dispense system, when in
-
stalling, cleaning or changing tips/nozzles, and
whenever you stop spraying/dispensing.
1. Follow the Pressure Relief Procedure on page
6.
2.
Disconnect the hydraulic hoses and plug all hy -
draulic connections and hoses.
CAUTION
Keep the hydraulic system clean
Always plug the hydraulic inlets, outlets and lines
when disconnecting them for any reason to avoid
introducing dirt and other contaminants into the
system.
3.
Disconnect the hydraulic motor from the displace -
ment pump as explained in your separate pump
manual.
4.
Pull the drain hose (1 13) of f the barbed adapter
(112).
Reconnecting the Hydraulic Motor
1. Reconnect the drain hose (1 13) to the barbed
adapter (112).
2.
Reconnect the hydraulic motor to the displacement
pump as explained in your separate pump manual.
3. Unplug all hydraulic connections and hoses. Re -
connect the hydraulic hoses.

 
Service
Motor Disassembly
1. Stand the motor upright. Remove the four screws
(104) and washers (105) holding the motor cap
(102) to the base (103). Lift the reciprocator (101)
of f the base (103) and lay it in a pan. Remove the
large o-ring (108) from the base (103). See Fig. 3.
2. Remove the cotter pin (1 1 1) and unscrew the ex -
tension rod (110) from the reciprocator displace -
ment rod (9). See Fig. 4.
3. Pull the oil deflector (109) of f the extension rod
(1 10). Remove the o-ring (1 17) and spacer
(124) from the rod and deflector .
4.
Unscrew the nuts (106) and washers (105) from
the reciprocator tie rods (37) and pull the motor
cap (102) of f the reciprocator (101). Remove the
o-ring (107) from the cap.
5.
Clean and inspect all parts. Replace parts as nec -
essary. T
o service the reciprocator (101), refer to
page 10.
03056
Fig. 3
1Grease.
104
105
102
101
103
108
120
34
1
112
Motor Reassembly
1. Grease the o-ring (107) and install it on the motor
cap (102). Install the motor cap, washers (105)
and nuts (106) on the reciprocator tie rods (37).
T orque the nuts to 29–31 ft–lb (39–42 N.m). See
Fig. 4.
2. Grease the o-ring (1 17). Install it in the inner
groove of the oil deflector (109). Slide the deflector
onto the extension rod (1 10), beveled side facing
up, until it seats. Slide the spacer (124) onto
the rod so it contacts the top of the deflector . See
Figs. 4 and 5.
3. Apply thread lubricant to the threads of the exten -
sion rod (1 10) and screw it into the reciprocator
displacement rod (9) until the pin holes align.
Install the cotter pin (1
11).
4.
Grease the large o-ring (108) and install it on the
top of the motor base (103). Set the reciprocator
(101) and motor cap (102) on the motor base. Ori -
ent the reciprocator fluid inlet (34) to the grounding
lug (120) as shown in Fig. 3.
5. Secure the motor cap (102) to the base (103) with
four washers (105) and screws (104). T ighten se -
curely.
03057
Fig. 4
1
3
4
2
101
9
102
105
111110
109
117
106
107
Grease.
Apply
thread lubricant.
T orque to 29–31 ft–lb
(39–42 N.m).
Beveled side faces up.
1
1
2
3
4
37
124
PTFE
PTFE

9308-330
Service
03058
Fig. 5



9111
110
124
107
Grease.
Apply thread lubricant.
Beveled side faces up.



117

103
104
105
102
101
109
108


10 308-330
Service
Reciprocator Service
Disassembly
NOTE:
Repair Kit 236–698 is available. For the best
results, use all the parts in the kit. Kit parts are marked
with an asterisk, for example (2*).
NOTE: When disassembling, lay out all parts in se -
quence, to make reassembly easier . Clean and inspect
all parts for wear or damage before reassembling. Re -
place as necessary .
1.
Remove the reciprocator from the motor base as
explained on page 8. Lay it on its side in a pan.
2. Unthread the tie rods (37) from the retainer (36)
and pull them out through the top of the reciproca -
tor
. It should not be necessary to remove the four
nuts (27) and lockwashers (28).
3. Unscrew the four fluid tube nuts (N) and remove
the tubes (32, 39). See Fig. 6. Allow excess oil to
drain from the reciprocator , then plug the fluid fit -
tings.
CAUTION
Keep the hydraulic system clean
Always plug the hydraulic inlets, outlets and lines
when disconnecting them for any reason to avoid
introducing dirt and other contaminants into the
system.
4.
Pull the top cylinder cap (1), cylinder (33), and dis -
placement rod (9) together of f the bottom cylinder
cap (35). Remove the o-ring (2) from the bottom
cap.
5.
Grasp the top cap (1) and pull the cylinder (33) of f.
Slide the cylinder of f the displacement rod (9). Be
careful not to damage the rod. Remove the o-ring
(2) from the top cap.
6. Lay the top cap (1) and displacement rod (9) on a
table. Place a clean rag around the yoke (4) to pre -
vent the detent balls (3) from popping out. Push
the yoke (4) sideways of f the valve sleeve (19)
while holding the balls (3) and spring (18) with the
rag, then carefully remove the balls and spring.
7. Inspect the valve sleeve (19), valve stop (25), and
spool (S) for damage. If any of these parts re -
quires replacement, unscrew the two screws (26)
holding the stop (25) to the spool (S). Remove the
stop and slide the sleeve (19) off the spool. If the
spool is damaged, replace the top cap (1).
NOTE: If any of these parts are being reused, thor -
oughly clean any adhesive residue from the screws
and female threads of the spool. Use a surface cleaner
such as chlorinated solvent on the threads and blow
dry with compressed air . If necessary, use a 10–24
unc–2b tap to remove adhesive from the female
threads.
8.
Remove the capscrew (23), sealing washer (22)
and o-ring (24) from the cap plate (29). Lift of f the
cap plate and remove the o-ring (20).
9. Hold the flats of the displacement rod (9) in a vise
and use a spanner wrench in the pin holes of the
piston (16) to screw it of f the rod. Remove the trip
rod (17) from the displacement rod.
CAUTION
Be careful not to scratch the outside of the dis -
placement rod.
10. Unscrew the nut (48) and remove the retainers
(11) and spring (12) from the trip rod (17).
11.
Slide the piston (16) of f the trip rod (17). Remove
the bearing (5), seal (6), and o-rings (7 and 8) from
the piston.
12. Inspect the yoke (4) and trip rod (17) for damage.
If either part requires replacement, slide the yoke
into Repair T
ool 189–305 and set the tool in a vise.
See Fig. 7. Use a wrench on the flats of the trip
rod and unscrew the rod from the yoke.
13. Pull the housing retainer (36) away from the bot -
tom cylinder cap (35).
14. Remove the block packings (14 and 49), wiper
(15), bearing (13), and o-ring (2) from the housing
retainer and bottom cylinder cap.

11308-330
Service
23
*24
22
29
31
32
1
4
19
*3
25
26 *18
*3
17
*2
33
*2
37
39
38
28
27
34
9
48*
11
12*
11
8*
16
7*
6*
5*
38
35
49*
13*
14*
15*
2*
36
Fig. 6
03063
N
S
N
32 (Ref)
N
39(Ref)
N
20*
50

12 308-330
Service
Reassembly
1.
Install the block packing (14*) and wiper (15*) in
the housing retainer (36). The spring of the block
packing and the lips of the wiper must face up .
Install the o-ring (2*) on the top surface of the re -
tainer
. See Fig. 7.
2. Install the bearing (13*) and block packing (49*) in
the bottom cylinder cap (35). The lips of the block
packing must face up.
3. Reassemble the housing retainer (36) and the bot -
tom cylinder cap (35).
4. T o reassemble the yoke (4) and trip rod (17), clean
the threads with primer or chlorinated solvent and
let dry for 3 to 4 minutes. Apply thread sealant to
the female threads of the yoke. Slide the yoke into
Repair T ool 189–305 and place the tool in a vise.
Using a wrench on the flats of the trip rod, screw
the rod into the yoke. T orque to 54–56 in–lb
(6.1–6.3 N.m).
5. Install the bearing (5*), o-ring (7*), and seal (6*) on
the piston (16). Install the second o-ring (8*) on the
underside of the piston. Slide the piston onto the
trip rod (17) so the wide end of the piston faces the
yoke (4).
6. Install the retainers (1 1) and spring (12*) on the trip
rod (17). Screw the nut (48*) onto the rod and ad -
just so the spring dimension is 1.580 +/– .015 in.
(40.13 +/– 0.38 mm). See the Detail in Fig. 7.
7. Hold the flats of the displacement rod (9) in a vise.
Slide the trip rod (17) into the displacement rod.
Use a spanner wrench in the pin holes of the pis -
ton (16) to screw it into the displacement rod.
T orque to 30–40 ft–lb (41–54 N.m).
8. Install the o-ring (20*) in the top cylinder cap (1),
then install the cap plate (29), o-ring (24*), sealing
washer (22), and capscrew (23).
9. T o reassemble the valve sleeve (19) and valve
stop (25), slide the sleeve (19) onto the valve
spool (S). (Either side of the sleeve can face up.)
Apply primer to the threads of the screws (26) and
let dry for 3 to 4 minutes. Apply 1 or 2 drops of
thread sealant to the female threads of the spool
(S). Install the stop (25) and torque the screws
(26) to 42–45 in–lb (4.7–5.1 N.m).
10. T o assemble the valve mechanism, use Repair
T ool 189–305 as follows:
a. Slide the yoke (4) into the repair tool, as
shown in the Detail in Fig. 7. Align the upper
detent holes (H) of the yoke with the center
line of the tool.
b. Insert the spring (18*) and one ball (3*) into the
valve stop (25). T ilt the valve stop and start
guiding it into the tool, making sure the ball is
sliding into the rounded slot in the tool.
c. Place the second ball (3*) at the other end of
the spring (18*) and push it in with your thumb
while rotating the valve stop (25) until the
spring is horizontal and the balls are in place.
Continue holding this assembly together
.
d.
Align the curved ends of the yoke with the
valve sleeve groove, then press the assem -
blies firmly together . Make sure the balls snap
into the upper detent holes (H) of the yoke (4),
and the curved ends of the yoke engage the
valve sleeve (19) groove. To remove the tool,
slide it over the trip rod (17).
11. Place the bottom cylinder cap (35) in a vise. Install
the o-ring (2*) in the cap. Set the cylinder (33) on
the bottom cap.
12. Install the o-ring (2*) in the top cylinder cap (1).
Make sure the hydraulic fittings (31, 34, and 38)
are oriented as shown in Fig. 6, then slide the dis -
placement rod (9) and piston (16) into the cylinder
(33) until it seats in the top cap.
CAUTION
When inserting the piston into the cylinder , carefully
guide the piston seal (6*) and bearing (5*) to pre -
vent damage to these parts.
13. Install the tie rods (37). If the nuts and washers
were removed, screw them onto the ends with
short threads.
14. Remove the plugs from the fluid fittings (31, 34
and 38). Install the tubes (32, 39) and tighten the
four fluid tube nuts (N).
15. Reinstall the reciprocator on the motor base as
explained on page 8.

13308-330
Service
03059
Fig. 7
1
3
4
2
03061
03060
29 38
22
20*
1
2*
37
4
39
5*
6*
17
33
35
2*
49*
36
14*
*15
*2
*13
34
9
32
*8
16
26
25
S
19
31 *24 23
*7
19 S
25
18* 3*
17
4
H
189–305
Tool
17
11
*12
11
*48
1.580 +/– .015 in.
(40.13 +/– 0.38 mm)
Spring faces up.
Lips face up.
Apply thread sealant to female threads.
T orque to 54–56 in–lb (6.1–6.3 N.m).
Wide end faces yoke (4).
Apply primer to threads and let dry 3 to 4 minutes.
Apply 1–2 drops of thread sealant to female threads.
T orque to 42–45 in–lb (4.7–5.1 N.m).
5
6
7
8
7
6 8
5
2
1
2
4
3
7
T
orque to 30–40 ft–lb (41–54 N.m).
9
9
6
6
4
3 6
6

14 308-330
Notes

15308-330
Parts
236–417 V iscountr I Motor, Series A
101
102
103
104
105
105
106
107
108
109
110
111
112
113
114
115
116
117
119 120
Y123
03062
124
Ref
No. Part No. Description Qty
101 236–418 RECIPROCATOR, hydraulic
See pages 16 and 17 for parts 1
102 189–079 CAP
, motor 1
103 189–068
BASE, motor 1
104 112–339 SCREW
, cap, socket hd;
3/8–24 unf–3a; 2.25 in. (57.2 mm) 4
105 100–133 WASHER, lock; 3/8 in. size 8
106 106–292 NUT
, hex; 3/8–24 unf–2b 4
107 106–274 O-RING; buna-N 1
108 112–343 O-RING; buna-N 1
109 189–080 DEFLECT
OR, oil 1
110 189–081 ROD, extension 1
111 100–103 PIN, cotter 1
112 103–875
ADAPTER, barbed; 1/8 npt(m);
fits 0.25 in. (6.3 mm) ID hose 1
113 054–104
HOSE, drain 6 ft
114 236–451 BOTTLE, drain 1
115 236–272
HOLDER, drain bottle 1
116 103–927 CLAMP
, hose 1
117 112–030 O-RING 1
119 104–582 WASHER, tab 1
120 104–029
LUG, grounding 1
123Y187–959
LABEL, warning 1
124 166–667 SPACER; 1
Y
Replacement Danger and W arning labels, tags and cards
are available at no cost.
PTFE

16 308-330
Parts
236–418 V iscountr I Reciprocator, Series A
03063
23
*24
22
29
*20
31
32
1
4
19
*3
25
26 *18
*3
17
*2
33
*2
37
39
38
28
27
34
32 (Ref)
39(Ref)
9
48*
11
12*
11
8*
16
7*
6*
5*
38
35
49*
13*
14*
15*
2*
36
Y10
50

17308-330
Parts
236–418 V iscountr I Reciprocator, Series A
Ref
No. Part No. Description Qty
Ref
No. Part No. Description Qty
1 236–594 TOP CAP ASSEMBLY 1
2* 106–274 O-RING; buna-N 3
3* 100–069
BALL; carbon steel 2
4 189–077 YOKE, valve 1
5* 178–207
BEARING, piston; bronze-filled 1
6* 178–226
SEAL, piston; glass-filled 1
7* 108–014 O-RING; buna-N 1
8* 105–765 O-RING; buna-N 1
9 189–070
ROD, displacement 1
10Y179–885
LABEL, warning 1
11 189–069 RETAINER, spring 2
12* 178–189 SPRING, compression 1
13* 112–342
BEARING, rod; bronze-filled 1
14* 112–340 P
ACKING, block; nitrile rubber 1
15* 112–341
WIPER, rod; nitrile rubber 1
16 189–205 PISTON 1
17 189–071 ROD, trip 1
18* 108–437 SPRING, compression 1
19 189–072 SLEEVE, valve 1
20* 104–093 O-RING; buna-N 1
22 178–179 W
ASHER, sealing 1
23 106–276 SCREW
, cap, hex hd; 3/8–24 unf–2a;
0.625 (16 mm) long 1
24* 155–685 O-RING; buna-N 1
25 181–885 STOP, valve 1
26 104–092 SCREW
, cap, socket hd;
10–24 unrc–3a; 0.625 (16 mm) long 2
27 106–292 NUT
, hex; 3/8–24 unf–2b 4
28 100–133 WASHER, lock; 3/8 in. size 4
29 178–181 PLA
TE, cap 1
31 106–470 ELBOW
, 90 _ ; 3/4–16 unf–2a;
fits 1/2 in. (13 mm) diameter tube 1
32 236–419
TUBE, inlet; w/3/4–16 unf–2b fittings 1
33 178–229 CYLINDER 1
34 107–197
TEE; 3/4–16 unf–2a 1
35 189–073 CAP
, cylinder , bottom 1
36 189–074 RET
AINER, housing 1
37 189–075 ROD, tie 4
38 110–792 ELBOW
, 90 _ ; 7/16–20 unf–2a x
9/16–18 unf–2a;
fits 3/8 in. (10 mm) diameter tube 2
39 236–420
TUBE, drain;
w/9/16–18 unf–2b fittings 1
48* 108–094 NUT
, hex, locking; w/nylon insert;
1/4–28 unf–3b 1
49* 112–561 P
ACKING, block; urethane 1
50 107–195
ADAPTER, straight thread, 37 _ flare;
3/4–16 unf–2a x 7/8–14 unf–2a
1
* These parts are included in Repair Kit 236–698, which
may be purchased separately .
Y Replacement Danger and W arning labels, tags and cards
are available at no cost.
PTFE
PTFE
PTFE

18 308-330
Accessories
Use Only Genuine Graco Parts and Accessories
Graco Approved Hydraulic Fluid
Premium, ISO grade 46 petroleum-based hydraulic oil
containing rust and oxidation exhibitors and anti-wear
agents. 210
_F (99_ C) Flash Point.
169–236 5 gallon (20 liter)
207–428 1 gallon (3.8 liter)
Grounding W ire Kit 222–011
25 ft (7.6 m) long,
12 gauge (1.5 mm
@) minimum
Hydraulic Shut-Off V alve
102–644 3/4 npt(f)
Motor Mounting Plate Kit 236–714
Consists of:
Adapter Plate 189–206,
four Screws 100–001,
four Lockwashers 100–214.
W all Bracket 206–221
Use to mount the V iscount to a wall.
Assembly T ool 189–305
Required for reassembling the motor .
Mounting Hole Layout
1
2
2.62” (67 mm) Dia. Cutout
Three 1/2–13 unc (2b) holes on a
3.5” (89 mm) dia bolt circle.
Three 0.45” (1 1.5 mm) countersunk
holes with M10 x 1.5 threaded
holes on a 4.92” (125 mm) bolt
circle.
Four 5/16–18 unc (2b) threaded
holes on a 6.4” (163 mm) dia bolt
circle for adapter plate mounting
holes.
3 Tie Rod Mounting
1
2
3
4
3
4


Technical Data
Maximum hydraulic fluid input pressure 1500 psi (105 bar) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum hydraulic fluid input volume 3 gpm (1 1.3 liter/min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid consumption rate 6.5 ounces (0.195 liter) per cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
or 1 gallon per 19.5 cycles
Maximum water content of hydraulic fluid 1 percent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum fluid temperature 130_ F (54_ C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Effective piston area 1.48 sq in. (9.55 cm @). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston rod diameter 1–3/8 in. (34.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke 4 in. (101.6 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thrust at 1500 psi (105 bar) 2220 lb (9875 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight with base 28 lb (124.6 N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loctiter is a registered trademark of Loctite Corporation. Perma-Locr and Perma-Bond r are registered trademarks of
Perma-Loc Company .
Dimensions
03054
21 in.
(533.4 mm)
1 1 in.
(279.4 mm)
3/4–16 unf
Hydraulic
Fluid Inlet
7 in. (177.8 mm)

 
The Graco Warranty and Disclaimers
WARRANTY
Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on
the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser ’ s sole remedy for breach of this
warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defec -
tive.
This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’ s written rec-
ommendations.
This warranty does not cover
, and Graco shall not be liable for , any malfunction, damage or wear caused by faulty installation,
misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco
equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, instal
-
lation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor
for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any
defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts,
labor and transportation.
DISCLAIMERS AND LIMITATIONS
The terms of this warranty constitute purchaser ’ s sole and exclusive remedy and are in lieu of any other warranties (express or
implied), including warranty of merchantability or warranty of fitness for a particular purpose , and of any non–contractual
liabilities, including product liabilities, based on negligence or strict liability . Every form of liability for direct, special or consequen -
tial damages or loss is expressly excluded and denied. In no case shall Graco’ s liability exceed the amount of the purchase price.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
Graco makes no warranty , and disclaims all implied warranties of merchantability and fitness for a particular purpose , with
respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not
manufactured by Graco (such as electric motor , switches, hose, etc.) are subject to the warranty , if any , of their manufacturer .
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
Graco Phone Numbers
TO PLACE AN ORDER , contact your Graco distrib -
utor
, or call this number to identify the distributor
closest to you: 1–800–367–4023 T oll Free.
FOR TECHNICAL ASSIST ANCE, service repair
information or assistance regarding the application of
Graco equipment: 1–800–543–0339 T oll Free
Sales Offices: Atlanta, Chicago, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)
Foreign Offices: Canada; England; Korea; Switzerland; France; Germany; Hong Kong; Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 308–330 1/94