Graco Viscount I 3000 User manual

Instructions
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1984, Graco Inc. is registered to I.S. EN ISO 9001
ViscountI 3000 Pump
Model 221080, Series A
With a Severe–Duty Displacement Pump*
1000 psi (7 MPa, 69 bar) Maximum Hydraulic Input Pressure
3000 psi (21 MPa, 207 bar) Maximum Fluid Outlet Pressure
* Severe–Duty Displacement Pumps have an abrasion-
and corrosion-resistant displacement rod and cylinder.
See manual 306981 for displacement pump parts and
service information.
US Patent No. 4,383,475
Patent 1984 Canada
Brevete 1984
Foreign Patents Pending
307623H
Parts

2307623H
Table of Contents
Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Hole Layout 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

307623H 3
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 15 for the maximum working pressure of this equipment.
Use 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.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 180F (82C) or below –40F (–40C).
Wear hearing protection when operating this equipment.
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.

4307623H
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin
can also cause serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
Do not point the gun/valve at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip/nozzle.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Be sure the gun/valve trigger safety operates before spraying.
Lock the gun/valve trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 8 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; and install or clean the spray tip.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
Use only Graco approved hoses. Do not remove any spring guard that is used to 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.
Keep clear of all moving parts when starting or operating the pump.
Before servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly.

307623H 5
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Ground the equipment and the object being sprayed/dispensed. Refer to Grounding on page 6.
If 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.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed/dispensed.
Keep the spray/dispense area free of debris, including solvent, rags, and gasoline.
Electrically disconnect all equipment in the spray/dispense area.
Extinguish all open flames or pilot lights in the spray/dispense area.
Do not smoke in the spray/dispense area.
Do not turn on or off any light switch in the spray/dispense area while operating or if fumes are
present.
Do not operate a gasoline engine in the spray/dispense 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.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

6307623H
Installation
Grounding
To reduce the risk of static sparking, ground the pump,
object being sprayed , and all spray/dispensing equip-
ment 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: loosen the grounding lug locknut (W) and
washer (X). Insert one end of a 1.5 mm2 (12 ga)
minimum ground wire (Y) into the slot in lug (Z)
and tighten the locknut securely. See Fig. 1. Con-
nect the other end of the wire to a true earth
ground. Order Part No. 237569 Ground Wire and
Clamp.
Fig. 1
Y
Z
W
X
2. Hydraulic hoses: use only electrically conductive
hoses.
3. Fluid hoses: use only electrically conductive fluid
hoses.
4. Hydraulic power supply: follow manufacturer’s
recommendations.
5. Spray gun/dispensing valve: grounding is obtained
through connection to a properly grounded fluid
hose and pump.
6. Fluid supply container: according to your local
code.
7. Object being sprayed: according to your local
code.
8. All solvent pails used when flushing, according to
your local code. Use only metal pails, which are
conductive, placed on a grounded surface. Do not
place the pail on a nonconductive surface, such as
paper or cardboard, which interrupts the grounding
continuity.
9. To maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
spray gun/dispensing valve firmly to the side of a
grounded metal pail, then trigger the gun/valve.
Install the Pump
CAUTION
Keep the hydraulic system clean
To reduce the risk of damaging the hydraulic power
supply, blow out all hydraulic lines with air, flush
thoroughly with solvent, and then blow out with air
again before connecting the lines to the reciprocator.
Always plug the hydraulic inlets, outlets and lines
when disconnecting them 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 hydraulic fluid.
CAUTION
Recommended Hydraulic Oil
Use Graco-approved Hydraulic Oil or the equivalent.
Order Part No. 169236 5 gallon (20 liter) or 207428 1
gallon (3.8 liter). 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 Graco
reciprocator, contact your Graco distributor. Un-
authorized use of lesser grade oil or substitutes may
void the warranty.
The Typical Installation shown in Fig. 2 is only repre-
sentative. Contact your Graco distributor for specific
information. Pump dimensions and mounting hole
layout are shown on page 14.
Hydraulic Power Supply
Be sure that the hydraulic power supply is equipped
with a suction filter to the hydraulic pump and a system
return line filter of 10 micron size. Carefully follow the
manufacturer’s recommendations on reservoir and
filter cleaning, and periodic changes of hydraulic fluid.

307623H 7
Installation
Fig. 2
C
P
D
R
EFHJ
L
G
Q
M
A
N
B
3/4 npt(m)
FLUID INLET
K
HYDRAULIC INLET
3/4 UNF–2A 37_(M) FLARE
HYDRAULIC OUTLET
7 8-14 UNF-2A 37 (M) FLARE
KEY
AFluid Hose to Gun
BFluid Drain Valve
CSuction Hose
DHydraulic Return Line
ESupply Line Shutoff Valve
FPressure Gauge
GFlow Control Valve
HPressure Reducing Valve
JAccumulator
KDrain Line
LHydraulic Supply Line
MHydraulic Power Supply
NGround Wire
PWet cup
QCheck Valve
RReturn Line Shutoff Valve
Hydraulic Lines
Supply Line (L): Connect a 1/2 in. minimum ID to the
3/4–16 UNF–2a, 37male flare inlet of the reciproca-
tor.
Return line (D): Connect a 5/8 in. minimum ID to the
7/8–14 UNF–2a, 37male flare outlet of the reciproca-
tor.
On the hydraulic supply line (L), install the following
accessories:
A shutoff valve (E) to isolate the system for servic-
ing.
A fluid pressure gauge (F) to monitor the hydraulic
oil pressure to the reciprocator and avoid overpres-
surizing the reciprocator or displacement pump
A pressure- and temperature-compensated flow
control valve (G) to prevent the reciprocator from
running too fast.
A pressure-reducing valve (H) with a drain line (K)
running directly into the hydraulic return line.
An accumulator (J) to reduce the hammering effect
caused by the reciprocator reversing direction.
On the hydraulic return line (D), install a shutoff valve
(R) for isolating the reciprocator for servicing.
WARNING
To reduce the risk of serious bodily injury, including
fluid injection, your system must include a drain
valve installed near the pump fluid outlet to help
relieve fluid pressure in the displacement pump and
hoses when shutting off the pump. See Fig. 2.
Install a fluid drain valve (B) and a grounded dispense
hose (A) to the 3/8 npt fluid outlet on the displacement
pump. Connect a suction hose to the 3/4 npt pump
fluid intake. See Fig. 2.

8307623H
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in-
jected through the skin and cause
serious injury. To reduce the risk of an
injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
are instructed to relieve the pressure,
stop spraying/dispensing,
check or service any of the system equipment,
or install or clean the spray tip/nozzle.
WARNING
Be sure you always shut off the supply line shutoff
valve (E) first, and then the return line shutoff valve
(R). This is to prevent overpressurizing the recipro-
cator or its seals. When starting up the hydraulic
system, open the return line shutoff valve first.
1. Lock the spray gun/dispensing valve trigger safety.
2. Close the supply line shutoff valve (E) first, then
the return line shutoff valve (R). Shut off the hy-
draulic power supply.
3. Unlock the gun/valve trigger safety.
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. Lock the gun/valve trigger safety.
6. Open the drain valve (required in your ystem),
having a container ready to catch the drainage.
7. Leave the drain valve open until you are ready to
spray/dispense again.
If you suspect that the spray 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
and relieve pressure gradually, then loosen completely.
Now clear the tip/nozzle or hose.
Before Startup
WARNING
Do not overpressurize the system
To reduce the risk of overpressurizing the system,
which could result in serious bodily injury, including
fluid injection:
Never exceed the maximum working pressure
of the lowest rated accessory in your system
(hydraulic input or fluid output), or the stated
maximum working pressures of this pump.
Regulate the hydraulic input and fluid output
pressures, as appropriate, to maintain safe
working pressures.
CAUTION
Hydraulic Oil Working Temperature
The recommended hydraulic oil operating tempera-
ture is 80 – 115F (27 – 45C). The reciprocator
seals will wear faster and leakage may occur if the
pump is operated at higher oil temperatures.
If the hydraulic oil temperature approaches 130F
(54C), check the hydraulic fluid supply cooling
system, filters, etc. and clean or repair as needed.
WARNING
Be sure the entire system and flushing pails are
properly grounded before flushing. Always use the
lowest possible pressure, and maintain firm metal-
to-metal contact between the gun and pail to
reduce the risk of static sparking and splashing.
Maintain firm metal-to-
metal contact between
gun and grounded
metal pail.
Before you start the pump, check the hydraulic fluid
level, and add fluid as necessary to fill the lines.
Flush the pump before using it for the first time to
remove the light oil which was left in after factory test.
Be sure the solvent used is compatible with the fluid to
be sprayed and the wetted parts of the pump.

307623H 9
Operation
Fill the displacement pump wet-cup (S) 1/3 full with
Graco Throat Seal Liquid or a compatible solvent, to
prevent fluid from drying on the displacement rod or
damaging the packings. See Fig. 3.
Fig. 3
S
Pump Startup
1. Turn on the hydraulic power supply.
WARNING
Be sure you always open the return line shutoff
valve (R) first, and then open the supply line valve
(E). This is to prevent overpressurizing the recipro-
cator or its seals. When starting up the hydraulic
system, open the return line shutoff valve first.
2. Open the return line shutoff valve (R) first, and
then open the supply line valve (E).
3. Slowly open the flow control valve.
4. Use the lowest pressure needed to get good fluid
flow or atomization. Higher pressures increase tip
wear and pump wear.
In a direct supply system, the pump will start when the
gun or valve is opened, and stall when it is closed.
In a circulating system, the pump will operate continu-
ously until the hydraulic power supply is turned off.
Shutdown and Care of the Pump
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
For overnight shutdown, relieve the pressure. Stop
the pump at the bottom of its stroke to prevent fluid
from drying on the exposed displacement rod and
damaging the throat packings.
Always flush the pump before the fluid dries on the
displacement rod. Never leave water or water-based
fluid in the pump overnight. First, flush with water or a
compatible solvent, then with mineral spirits. Relieve
the pressure, but leave the mineral spirits in the pump
to protect the parts from corrosion.

10 307623H
Maintenance
Hydraulic leaking at the reciprocator fittings. All of
the fittings (7, 8 and 10) going into the upper and lower
cylinder caps are self–sealing and have replaceable
o–rings (24, 25). See Parts, page 13. If you experi-
ence any leaking at these fittings, tighten them. If the
leaking persists, remove the fitting and replace the
worn o–ring.
Check the tightness of the packing nut weekly.
Always follow the Pressure Relief Procedure on page
8 before adjusting it. The packing nut should be tight
enough to stop leakage, but no tighter. Overtightening
will compress and damage the packings and result in
pump leaking.
Carefully monitor the fluid supply.If the pump
empties the supply container, air is sucked into the
pump, causing it to run too fast and to be damaged. If
the pump runs too fast, shut it off immediately. Fill the
supply container and prime the pump and hose to
remove all air, or flush the pump and hose with a
compatible solvent and leave it filled with an oil-base
solvent to protect pump parts from corrosion.
CAUTION
Never leave water-based fluid or air in the pump
when it is not in use. Flush the pump and fill it with
mineral spirits or other oil-based solvent to prevent
pump corrosion or fluid hardening in it.