Graco 221-181 Operation manual

INSTRUCTIONS–P ARTS LIST 307–866
Rev. B
Supersedes A
This manual contains IMPORT ANT
WARNINGS AND INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
CONVERSION/REPAIR KIT 221–181
To repair Quiet Viscount I Hydraulic Motor, Model 221–168
To convert a Standard Viscount motor, Models 210–107,
217–022 and 217–338 to a Quiet–style motor.
U.S. Patent No. 4,792,291
U.K. Patent No. 2,226,089
French Patent No. 88 16726
Other Foreign Patents Pending
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including
fluid injection, splashing in the eyes or skin, or injury
from moving parts, always follow this procedure
when
shutting of f the pump, checking or servicing
any part of the system, installing or changing spray
tips and whenever you stop spraying.
1. Engage the gun/dispensing valve safety latch.
2. T urn of f the hydraulic power supply .
3.
Disengage the gun/valve safety latch.
4. Hold a metal part of gun/valve firmly to a
grounded
metal pail. T rigger to relieve pressure.
5. Engage the safety latch again.
6. Open the pump drain valve (required in system),
having a container ready to catch the drainage.
7. Leave the drain valve open until you are ready to
spray again.
WARNING
If you suspect the spray tip or hose is completely
clogged
or pressure is not fully relieved after follow -
ing these steps,
VERY SLOWLY loosen hose end
coupling
and relieve pressure gradually , then loosen
completely. Now clear the tip or hose obstruction.
CAUTION
Cleanliness
is essential when repairing hydraulic mo -
tors.
A void getting dust or dirt into the motor .
NOTE: Complete warnings and instructions are in
manuals
307–158 and 307–865.
NOTE: Always replace retaining plugs and springs
when
replacing spool. Kit parts are marked in the
text with two asterisks, for example (37**).
Disassembly
1. Follow the Pressure Relief Procedure Warning.
Disconnect
all lines from motor . Remove pump from
mounting. Disconnect motor from pump.
CAUTION
Plug
the hydraulic lines immediately to prevent con -
tamination
of the hydraulic system.
2. Place the hydraulic motor in a bench vise.
3. For Models 221–168 and 210–107 only: Remove
the
drip pan screws (4) and drip pan (50) from base
(42). Unscrew the retainer screw (6). Remove the
drip
cover (31) from the piston (49). Refer to the Parts
Drawing on page 3.
4. Unscrew both hydraulic tube (48) compression nuts.
Remove the tube. Drain the oil into a pan. Remove
the
screws (8) holding the end cap (44).
5. Push the piston (49) up as far as possible.
To prevent damage to the spool (37) and upper hous -
ing
(40), be sure the detent assemblies are removed
before removing the end cap (44) and bearing and
guide
(51). See Step 6.
CAUTION
6. Remove one detent assembly –
plug (28), gasket
(25),
spring (29), guide (27), ball (7) . If parts stick in
the upper housing (40), turn the motor over and tap
lightly. Do not allow the parts to fall into the motor .
Repeat
for the other detent assembly .
7.
Loosen the four tie rod locknuts (3).
8. Remove the motor and lay on its side in a pan.
9. Remove the four tie rod locknuts (3), the four tie rods
(35) and washers (1). It is not necessary to remove
the
crown nuts (22) from the rod.
CAUTION
With
the tie rods removed, the assembly may sepa -
rate at the joints between the cylinder (39) and the
upper
and lower housings (40 & 41).
10. Remove the capscrews (8) and end cap (44).
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
 COPYRIGHT 1987, GRACO INC.

 
11. Remove the stop plug (43) from the upper housing
(40). Pull the upper housing 2 to 3 inches off the
cylinder
(39). Rock the housing to work it free. Do not
remove the cylinder from the lower housing (41).
12. Hold the trip rod (36) steady with an adjustable
wrench
on the flats of the rod, and remove the top hex
nut (20) from the trip rod.
13. Lift the upper housing assembly (40) with the spool
guides
(34) and springs (38) still inside.
NOTE: If you are not using the repair kit, inspect the trip
rod above the shoulder for scoring or damage.
There must be no reduction in rod diameter. If
there
is, replace the rod.
14. Pull the trip rod (36) and piston (49) from the lower
housing
(41) and cylinder (39). Place the flats of the
piston in a vise. Use a hammer and punch to remove
the retainer (32). Remove the trip rod from the piston.
15. Remove the trip rod locknut (9) and piston stop (33).
If the piston is being replaced, remove and save the
compression spring (55) and the o–ring (26). New
compression
rings (19) are supplied with the kit.
CAUTION
Use
care when removing the piston from the cylinder
to avoid scratching the cylinder wall or the piston.
16. Remove the cylinder (39) and lower housing (41).
Remove
the seals (23) from the bottom of the lower
housing.
Reassembly
1. Lubricate the seals (23**) with light oil. Install in the
lower housing (41)
with lips facing top of motor .
Install
the o–ring (12**) on the lower housing. Install
the lower housing, making sure it seats properly.
Install the o–rings (13**) on the cylinder (39), and
install
the cylinder on the lower housing.
2. Install the compression spring (55) inside the piston
(49). The compression rings (19**) should be
positioned
with the joints 180 opposed.
3. Install the piston stop (33**) and locknut (9) on the trip
rod (36**). Slide the trip rod into the piston (49) and
spring (55). Apply low strength sealant such as
Loctiter
TL–222 to the retainer threads (32). With the
piston flats in a vise, screw the retainer all the way
into
the piston.
Screwing the retainer (32) all the way into the piston
(49) is essential to prevent the retainer from backing
out during operation and damaging the motor .
CAUTION
4. Using a hose clamp to compress the piston rings
(19**), install the trip rod and piston in the cylinder
(39) and lower housing (41) until the tops of the
piston
and cylinder are flush.
5. Clamp the trip rod flats with a wrench, and then install
the upper housing (40), so the tube fittings align with
those on the lower housing. The trip rod will protrude.
6. Slide the lower trip rod guide (34**) and spring (38**)
onto the trip rod. Install the spool (37**) with the
detent at the top. Install the top spring (38**) and
guide (34**) on the trip rod. Hold the flats of the trip
rod
with an adjustable wrench and install the top hex
nut (20). Slide assembly into upper housing (40).
7. Place the o–ring (1 1**) on the stop plug (43**), then
place the plug on the spool (37**). Install the end cap
(44), using low strength sealant on the screws (8).
Install
the tie rods (35) and washers (1).
To prevent damage to the spool (37) and upper
housing
(40), be sure the end cap (44) and bearing
and guide (51) are installed before installing the
detent
assemblies. See Step 8.
CAUTION
8. With the motor on its side, install the detent
assemblies: ball (7), guide (27 –
with concave
surface
toward ball ), spring (29**), gasket (25**) and
retaining plug (28**). Repeat for the other detent
assembly.
9. Install the hydraulic tube (48) and tighten the
compression
nuts to 40–60 ft–lb (54–82 N.m).
10. Torque the crown nuts (22) and tie rods (35) to 70–80
ft–lb (95–108 N.m).
11. Apply low strength sealant to the lower threads of the
tie rods (35) and torque the four tie rods locknuts (3)
to 20–30 ft–lb (27–41 N.m).
12. Be sure the o–ring (26) is in place in the groove on the
bottom half of the piston (49). Install the drip cover
(31) and screw (6) on the bottom of the piston (49).
Install the drip pan (5) and screws (4), making sure
the
drain adapter aligns with the drain port in the base
(42).
13. Connect the pump and motor, and all fluid lines.
Install
in your system. Reconnect the ground wire.
PARTS LIST
Repair Kit 221–181
Includes items listed below
Ref
No. Part No. Description Qty
11 104–093 O–ring 1
12 104–280 O–ring 1
13 104–095 O–ring 2
19 104–103
Ring, piston, compression 2
23 104–203
Seal, v–block 2
25 150–111 Gasket 2
28 167–431 Plug 2
29 108–522 Spring 2
33 181–243 Stop 1
34 183–659 Guide 2
36 171–407 Rod 1
37 183–658 Spool 1
38 171–411 Spring 2
43 171–416 Plug 1

 
PARTS DRA WING
CC
44 21
22
1
40
7
27 29**
25**
28**
61
20
34**
38**
37**
38**
34**
51
24
36**
33**
9
55
49
14
16
56
57
54 **11
**43
**26
**13
41
13**
39
35
12** 5253
42
5
45
58
31
6
10
50
4
59
17 2
56
19**
MUST BE
POSITIONED
WITH JOINTS
OPPOSED
8
48
TORQUE TO
40–60 ft–lb
(54–82 N.m)
3
TORQUE TO
20–30 ft–lb
(27–41 N.m)
32
22
TORQUE TO
70–80 ft–lb
(95–108 N.m)
30
18
PRESS FIT IN BASE;
INSPECT IN PLACE
23**
LIPS MUST F ACE
UP T OW ARD T OP
OF MOT OR
NOTE:
The corresponding bold
letters (C) refer to the
tubing connection.

4 307-866
THE GRACO W ARRANTY 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 defective. This
warranty applies only when the equipment is installed, operated and maintained in accordance with
Graco’s
written recommendations.
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, installation, 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 LIMIT ATIONS
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 CONSEQUENTIAL DAMAGES
OR
LOSS IS EXPRESSL Y 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 W ARRANTY
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 MANUF ACTURED 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.
IMPORTANT PHONE NUMBERS
TO PLACE AN ORDER , contact your Graco distributor ,
or call this number to identify the distributor closest to
you:
1–800–328–0211 T oll Free
FOR TECHNICAL ASSISTANCE, service repair infor-
mation
or assistance regarding the application of Graco
equipment: 1–800–543–0339 T oll Free
Factory Branches: Atlanta, Dallas, Detroit, Los Angeles, Mt. Arlington (N.J.)
Subsidiary and Affiliate Companies: Canada; England; Switzerland; France; Germany; Hong Kong; Japan; Korea
GRACO INC. P .O. BOX 1441 MINNEAPOLIS, MN 55440–1441
PRINTED IN U.S.A. 307–866 1 1–87 Revised 12–92