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Graco Viscount I Plus Operation manual

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Instructions – Parts List
PLUS
ViscountrI Hydraulic Motor
Used as hydraulic drive for reciprocating pumps.
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
Parts 236417, Series A, and 261466, Series A
Hydraulic Motor
Parts 236418, Series C, and 253608, Series A,
Hydraulic Reciprocator
US and Foreign Patents Pending
See also Manual 311211, High–FloRPumps
308330F
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 22 for maximum working pressures.
03054
236417 Motor Shown
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1994, Graco Inc. is registered to I.S. EN ISO 9001
2 308330
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing and Parts List 18. . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 19. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 24. . . . . . . . . . . . . . . . . . . . . . . . . .
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.
WARNING
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 not sure, 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 of the lowest rated system component. This equip-
ment has a 1500 psi (10.5 MPa, 105 bar) maximum hydraulic input pressure.
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 kink or overbend hoses or 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 66_C (150_F) or below –40_C (–40_F).
DWear hearing protection when operating this equipment.
DDo not move or lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
3308330
WARNING
SKIN INJECTION HAZARD
Spray from the gun/valve, leaks or ruptured components can inject fluid into your body and cause ex-
tremely 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 is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate surgical treatment.
DDo not point the gun/valve at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip/nozzle.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the gun/valve when spraying/dispensing.
DBe sure the gun/valve trigger safety operates before spraying/dispensing.
DLock the gun/valve trigger safety when you stop spraying/dispensing.
DFollow the Pressure Relief Procedure on page 7 if the spray tip/nozzle clogs and before clean-
ing, checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
DUse only Graco approved hoses. Do not remove hose spring guards, which help protect the hose
from rupture caused by kinks or bends near the couplings.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore checking or servicing the equipment, follow the Pressure Relief Procedure on page 7 to
prevent the equipment from starting unexpectedly.
4 308330
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and re-
sult in a fire or explosion and serious injury.
DGround the equipment and the object being sprayed. Refer to Grounding on page 5.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing 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 sprayed/dispensed.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DBefore operating this equipment, electrically disconnect all equipment in the spray/dispensing area.
DBefore operating this equipment, extinguish all open flames or pilot lights in the spray/dispensing
area.
DDo not smoke in the spray/dispensing area.
DDo not turn on or off any light switch in the spray/dispensing area while spraying/dispensing or
while operating if fumes are present.
DDo not operate a gasoline engine in the spray area.
DIf the hydraulic oil temperature approaches 130_F (54_C), shut off the motor and check the
hydraulic supply cooling system, filters, etc.
DKeep a fire extinguisher in the work 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.
5308330
Installation
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE AND EXPLOSION
HAZARD on page 4.
1. Pump: loosen the grounding lug locknut (W) and
washer (X). Insert one end of a 12 ga. (1.5 mm2)
minimum 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 Fig. 1.
Order Graco Part. No. 237569.
2. Hydraulic hoses and fluid outlet hoses: use only
electrically conductive hoses.
3. Hydraulic power supply: follow manufacturer’s
recommendations.
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. To maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
gun/valve firmly to the side of a metal pail, and
then open the gun/valve.
Fig. 1
WXZ
Y
6 308330
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.
Motor mounting plate kit 236714 (P) is available;
contact your Graco distributor for more information.
Be sure that your power supply is equipped with a
suction filter to the hydraulic pump and a system return
line filter of 10 micron size.
CAUTION
Keep the hydraulic system clean
To 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 recommendations
on reservoir and filter cleaning, and periodic changes
of the hydraulic fluid. The maximum water content of
the hydraulic oil is 1 percent.
Install the Drain Bottle
1. Push the drain hose (113) securely onto the
barbed adapter (112). See Fig. 2.
2. Position the holder (115) on a pump tie rod (C) and
secure with the hose clamp (116). Place the drain
bottle (114) in the holder.
3. Place the drain hose (113) in the drain bottle so it
hangs well down inside the bottle. Adjust the
position of the holder, if necessary.
03139
Fig. 2
113112
115
114
116
A
C
B
P
7308330
Operation
Pressure Relief Procedure
WARNING
SKIN INJECTION HAZARD
Fluid under high pressure can be in-
jected through the skin and cause seri-
ous injury. To reduce the risk of an injury
from injection, splashing fluid, or moving parts, fol-
low the Pressure Relief Procedure whenever you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray tips.
1. Lock the spray gun/dispensing valve safety latch.
2. Close the supply line shutoff valve(s) first, then the
return line shutoff valve(s). In a multi-pump sys-
tem, do this at each pump to isolate the pumps.
3. Unlock the gun/valve safety latch.
4. Hold a metal part of the gun firmly to the side of a
grounded metal pail, and trigger the gun/valve to
relieve pressure.
5. Lock 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 gradually, then loosen completely. Now clear
the obstruction.
Startup
Before each use, check the hydraulic fluid level and
add fluid as necessary to fill the lines.
To start the pump, turn on the hydraulic power supply.
Open the return line shutoff valve first,then open the
supply line shutoff valve.
WARNING
Hydraulic Oil Temperature
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 80–115_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. Order Part No. 169236, 5 gal. (19 liter)
or 207428, 1 gal. (3.8 liter). 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 your Graco distributor. Unauthorized use
of lesser grade oil or substitutes will void the
warranty.
Shutdown & Care
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
Relieve the pressure. Always shut off the supply line
shutoff valve first,and then the return line shutoff
valve. This is to prevent overpressurizing the motor or
its seals. When starting the hydraulic system, open the
return line shutoff valve first.
8 308330
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
Relieve the pressure before you check or service any
system equipment.
Check all possible problems and solutions before
disassembling the motor.
Problem Cause Solution
Reciprocator stops running. Worn valve or valve balls (3);
broken valve spring (18).
Repair valve. See page 13.
Broken trip rod (17), spring (12) or
retainers (11).
Replace parts. See page 13.
Poor performance or reduced effi-
ciency.
Worn piston seals (5, 6, 7). Replace seals. See page 13.
Oil leaking down extension rod. Worn o-ring (117, 121, or 122) in
oil deflector.
Replace o-ring. See page 9.
Oil leaking around cylinder. Worn cylinder o-rings (2). Replace o-rings. See page 13.
Loose tie rods (37). Tighten nuts (106). See page 9.
Oil leaking around inlet or return
tube fittings.
Loose fittings or worn fitting
o-rings.
Tighten or replace fittings (31, 34,
38). See page 13.
Excessive oil in drain bottle, or
bottle needs frequent emptying.
Worn seals in bottom cylinder cap. Replace seals (2, 15, 14 and 49).
See page 13.
Service
Tools Required
DSet of allen wrenches
DSet of socket or box wrenches
DAdjustable wrench
DTorque wrench
DSpanner wrench
DO-ring pick
D10–24 unc–2b tap
DVise
DShallow metal or plastic pan (approx. 12 x 20 in.)
DRepair Tool 189305
DThread lubricant
DLithium-base grease
DFresh Loctiter242 and 609 thread sealants and
LoctiterPrimer T or Perma-Locr115 thread seal-
ant and Perma-BondrSurface Conditioner I
DChlorinated solvent
Disconnecting the Hydraulic Motor
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
1. Relieve the pressure.
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 (113) off the barbed adapter
(112).
Reconnecting the Hydraulic Motor
1. Reconnect the drain hose (113) 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.
Reconnect the hydraulic hoses.
9308330
Service
Motor Disassembly
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
1. Relieve the pressure.
2. 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)
off the base (103) and lay it in a pan. Remove the
large o-ring (108) from the base (103). See Fig. 3.
3. For model 236417 only, remove the cotter pin (111)
and unscrew the extension rod (110) from the
reciprocator displacement rod (9). See Fig.
NO TAG.
4. Remove deflector.
Model 236417, pull the oil deflector (109) off the
extension rod (110). Remove the two o-rings (117)
from the rod and deflector.
Model 261466, remove the retaining o–ring and
slide the deflector off the rod.
5. Unscrew the nuts (106) and washers (105) from
the reciprocator tie rods (37) and pull the motor
cap (102) off the reciprocator (101). Remove the
o-ring (107) from the cap.
6. Clean and inspect all parts. Replace parts as
necessary. To service the reciprocator (101), refer
to page 13.
03056
Fig. 3
1Grease.
104
105
102
101
103
108
120
34
1
112
Model 236417
10 308330
Service
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).
Torque the nuts to 29–31 ft–lb (39–42 NSm). See
Fig. 4.
2. Connect deflector.
Model 236417 (see Figs.4 and 5), grease the two
o-rings (117). Install one of them in the inner
groove of the oil deflector (109). Slide the deflector
onto the extension rod (110), beveled side facing
up, until it seats. Slide the other o-ring (117) onto
the rod so it contacts the top of the deflector.
Model 261466 (see Figs. 4 and 6), grease the
thinner o–ring (121) and install on the displacement
rod (9). Slide the deflector onto the displacement
rod, beveled side facing up, until it seats. Install
the thicker o–ring (122).
3. For model 236417 only, apply thread lubricant to
the threads of the extension rod (110) and screw it
into the reciprocator displacement rod (9) until the
pin holes align. Install the cotter pin (111).
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.
Orient 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). Torque the
screws to 29–31 ft-lb (39–42 NSm).
Fig. 4
03057
1
3
4
2
101
102
105
111
110
109
117 106
107
Grease.
Apply thread lubricant.
Torque to 29–31 ft–lb
(39–42 NSm).
Beveled side faces up.
1
1
2
3
4
37
ti9005a
9
37
9
101
107
1
102
109
4
105
106 3
121
1
122
1
Model 236417
Model 261466