Graco Viscount 24E337 Operation manual

Instructions - Parts List
Viscount®4-Ball Pumps 3A0537M
EN
Hydraulic-powered pumps for low
pressure, high volume circulation of
finishing materials.
Do not use for flushing or purging
lines with caustics, acids, abrasive
line strippers, and other similar
fluids. For professional use only.
See page 3 for model information, including
maximum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in
this manual. Save these instructions.
TI15609a
Viscount II
Pump with
4000cc 4-Ball
Lower
II 2 G c IIB T3

Related Manuals
23A0537M
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pumps with 3000cc or 4000cc 4-Ball Lowers . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stand Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Wall Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flush Before Using Equipment . . . . . . . . . . . . . . 7
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . 10
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 10
Stop the Pump at the Bottom of Its Stroke . . . . 10
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preventive Maintenance Schedule . . . . . . . . . . 11
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mix Tank Volume . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic Power Supply Check . . . . . . . . . . . . . 11
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Changing the TSL . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Reassemble the Coupling Adapter and
Tie Rods to the Motor . . . . . . . . . . . . . . . . . 15
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Viscount II Pumps with 3000cc or
4000 cc 4-Ball Lowers . . . . . . . . . . . . . . . . . 16
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Motor Mounting Hole Diagram . . . . . . . . . . . . . . . 18
Mounting Stand Hole Layout . . . . . . . . . . . . . . . . 18
255143 Wall Mount Bracket . . . . . . . . . . . . . . . . . . 19
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3000 and 4000cc Pumps with
Viscount II Motor . . . . . . . . . . . . . . . . . . . . . 20
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 20
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 22
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 22
Related Manuals
Part No. Description
308048 Viscount II Hydraulic Motor manual
3A0540 4-Ball Lower manual (3000cc and 4000cc)

Models
3A0537M 3
Models
Pumps with 3000cc or 4000cc 4-Ball Lowers
Model No. Series
Maximum Pump
Working Pressure
psi (MPa, bar) Lower Size Motor
Connection
Style Material
Rod
Material
Cylinder
Material
24E337 A 400 (2.8, 28.0) 3000cc Viscount II npt cst Chromex Chrome
24E338 A 400 (2.8, 28.0) 3000cc Viscount II npt sst Chromex Chrome
24E339 A 400 (2.8, 28.0) 3000cc Viscount II npt sst Ultralife Ultralife
24E340 A300 (2.1, 21.0) 4000cc Viscount II npt cst Chromex Chrome
24E341 A300 (2.1, 21.0) 4000cc Viscount II npt sst Chromex Chrome
24E342 A300 (2.1, 21.0) 4000cc Viscount II npt sst Ultralife Ultralife

Warnings
43A0537M
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in the work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in a well-ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep the work area free of debris, including solvent, rags, and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are
present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold the gun firmly to the side of a grounded pail when triggering into a pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use the equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable
vapors. To help prevent fire and explosion:
• Clean plastic parts only in a well-ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in the equipment work area.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or ser-
vicing the equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swal-
lowed.
• Read the Safety Data Sheet (SDS) to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

Warnings
3A0537M 5
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system compo-
nent. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request a Safety Data Sheet (SDS) from your distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and
follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufac-
turer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut, or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, fol-
low the Pressure Relief Procedure and disconnect all power sources.
WARNING

Installation
63A0537M
Installation
Grounding
Pump: use a ground wire and clamp. See FIG. 1.
Loosen the locknut (W) of the grounding lug (Z). Insert
one end of the wire (Y) in the ground lug and tighten the
locknut securely. Connect the ground clamp to a true
earth ground. Order Part No. 237569, Ground Wire and
Clamp.
Air and fluid hoses: use only electrically conductive
hoses with a maximum of 500 ft. (150 m) combined
hose length to ensure grounding continuity. Check the
electrical resistance of hoses. If total resistance to
ground exceeds 25 megohms, replace hose immedi-
ately.
Hydraulic power supply: follow manufacturer’s recom-
mendations.
Surge tank: use a ground wire and clamp.
Dispense valve: ground through a connection to a
properly grounded fluid hose and pump.
Fluid supply container: follow local code.
Object being sprayed: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive sur-
face, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray gun
firmly to the side of a grounded metal pail, then trigger
the gun.
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
FIG. 1 Ground Wire
TI15854a
Z
Y
W

Installation
3A0537M 7
Stand Mount
Mount the pump in the accessory pump stand (B). Use
Part No. 218742 Stand for 3000 and 4000cc Pumps
(see FIG. 2, page 9).
See Mounting Stand Hole Layout on page 18. Secure
the stand to the floor with M19 (5/8 in.) bolts which
engage at least 152 mm (6 in.) into the concrete floor to
prevent the pump from tipping.
Wall Mount
1. Ensure the wall is strong enough to support the
weight of the pump assembly and accessories, fluid,
hoses, and stress caused during pump operation.
2. Ensure that the mounting location has sufficient
clearance for easy operator access.
3. Position the wall bracket at a convenient height,
ensuring that there is sufficient clearance for the
fluid suction line and for servicing the lower.
4. Drill four 7/16 in. (11 mm) holes using the bracket as
a template. Use any of the three mounting hole
groupings in the bracket. See 255143 Wall Mount
Bracket, page 19.
5. Bolt the bracket securely to the wall using bolts and
washers designed to hold in the wall’s construction.
6. Attach the pump assembly to the mounting bracket.
7. Connect air and fluid hoses.
Plumbing
Install a fluid shutoff valve (D) between the mix tank (A)
and the pump.
When using a stainless steel pump, use stainless steel
plumbing to maintain a corrosion-resistant system.
Flush Before Using Equipment
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid con-
taminating your fluid with oil, flush the equipment with a
compatible solvent before using the equipment. See
Flushing, page 11.

Installation
83A0537M
Accessories
Install the following accessories in the order shown in
FIG. 2, using adapters as necessary.
Hydraulic Power Supply
Be sure the power supply can provide sufficient power to
the motor. Be sure the power supply is equipped with a
suction filter to the hydraulic pump.
Hydraulic Supply Line
• For Viscount I Plus motors, the hydraulic inlet on the
motor is 3/4 in., 37° flare. Use a minimum 1/2 in. (13
mm) ID hydraulic supply line (L).
• For Viscount II motors, use a minimum 13 mm (1/2
in.) ID supply line (L). The motor has a 3/4 npt(f)
hydraulic oil supply fitting.
•Supply line shutoff valve (S): isolates the motor
when servicing the system.
•Hydraulic fluid pressure gauge (P): monitors the
hydraulic oil pressure to the motor to avoid over-
pressurizing the motor or lower.
•Pressure- and temperature-compensated flow
control valve (T): prevents the motor from running
too fast, which can damage it.
•Pressure reducing valve (N), which has a drain
line (M) running to the return line (K): controls the
hydraulic pressure to the motor.
Hydraulic Return Line
• For Viscount I Plus motors, the hydraulic outlet on
the motor is 7/8 in., 37° flare. Use a minimum 5/8 in.
(16 mm) ID hydraulic return line (K).
• For Viscount II motors, use a minimum 22 mm (7/8
in.) ID return line (K). The motor has a 1 in. npt(f)
hydraulic oil return fitting.
•Return line shutoff valve (R): isolates the motor
when servicing the system.
•Return fluid filter (J): removes residue from the
hydraulic fluid to help keep the system running
smoothly (10 micron size).
Fluid Line
For typical installation, see FIG. 2 on page 9.
•Fluid filter: with a 60 mesh (250 micron) stainless
steel element to filter particles from the fluid as it
leaves the pump.
•Fluid drain valve (U): required in your system, to
relieve fluid pressure in the hose and gun.
•Fluid shutoff valve (D): shuts off fluid flow.
NOTICE
The hydraulic power supply must be kept clean at all
times to avoid damage to the motor and hydraulic
power supply.
1. Blow out hydraulic lines with air and flush thor-
oughly before connection to the motor.
2. Plug hydraulic inlets, outlets, and line ends when
disconnecting them for any reason.
NOTICE
To avoid damage to the pump, never use the return
line shutoff valve to control the hydraulic flow. Do not
install any flow control devices on the hydraulic return
line.

Installation
3A0537M 9
Key:
AMixTank
B 218742 Pump Stand
C Fluid Supply Line; 1-1/2 in. (38 mm) minimum diameter
D Fluid Shutoff Valve
E Fluid Line; 1 in. (25 mm) minimum diameter
F Surge Tank Stand
G Surge Tank
J 10 Micron Return Filter
K Hydraulic Return Line
L Hydraulic Supply Line
M Drain Line
N Pressure Reducing Valve
P Hydraulic Pressure Gauge
R Return Line Shutoff Valve
S Supply Line Shutoff Valve
T Flow Control Valve
U Fluid Drain Valve (required)
Y Ground Wire (required; see page 6 for installation)
FIG. 2. Typical Installation for 3000 and 4000cc Pumps (Viscount II Motor Shown)
K
L
F
A
U
B
D
G
D
E
U
D
R
NPS
J
C
M
T
Y
TI15856a

Operation
10 3A0537M
Operation
Pressure Relief Procedure
1. Shut off the hydraulic supply line valve (S) first, then
the return line valve (R).
2. Open the dispensing valve, if used.
3. Open all fluid drain valves (U) in the system, having
a waste container ready to catch drainage. Leave
drain valve(s) open until you are ready to pump
again.
Prime the Pump
1. Fill the TSL reservoir to the Maximum fill line with
Throat Seal Liquid (TSL). See FIG. 3 on page 12.
NOTE: During operation the TSL level in the reservoir
will fluctuate slightly at pump changeover.
2. Close the flow control valve (T) by turning knob
counterclockwise reducing pressure to zero. Close
the supply line shutoff valve (S) and the return line
shutoff valve (R). Also verify that all drain valves (U)
are closed.
3. Check that all fittings throughout system are tight-
ened securely.
4. Start the hydraulic power supply.
5. Open the return line shutoff valve (R), then the sup-
ply line shutoff valve (S). Slowly turn the flow control
valve (T) clockwise, increasing pressure until pump
starts.
6. Cycle pump slowly until all air is pushed out and
pump and hoses are fully primed.
7. Verify that pump actuations are priming the pump
wet-cup. If not, confirm that the TSL pump piston is
being depressed at bottom changeover, and that
reservoir check valves are not stuck closed.
8. Close the fluid shutoff valve (D) downstream of the
pump. The pump should stall against pressure.
NOTE: In a circulation system, the pump operates con-
tinuously until the power supply is shut off. In a
direct-supply system, the pump starts when the dis-
pense valve is opened, and stops when the dispense
valve is closed.
Stop the Pump at the Bottom of
Its Stroke
Relieve the pressure when you stop the pump for any
reason. Stop the pump on the downstroke, before the
motor changes over.
Shutdown
Follow the Pressure Relief Procedure, page 10.
Always flush the pump before the fluid dries on the dis-
placement rod. See Flushing on page 11.
NOTICE
When shutting down the hydraulic system, always
shut off the hydraulic supply line shutoff valve (S) first,
and then the return line shutoff valve (R) to prevent
overpressurizing the motor or its seals. When starting
the hydraulic system, open the return line shutoff
valve first.
NOTICE
Failure to stop the pump at the bottom of its stroke
allows fluid to dry on the piston rod, which can dam-
age the throat packings and the TSL pump piston seal
when the pump is restarted.