Graco Viscount II Operation manual

Instructions - Parts List
Viscount®4-Ball Pumps 3A0537G
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.
TI15600a
TI15609a
Viscount II
Pump with
4000cc 4-Ball
Lower
TI15601a
Viscount II
Pump with
2000cc 4-Ball
Lower
Viscount I Plus
Pump with
1000cc 4-Ball
Lower
II 2 G
c IIB T3

Related Manuals
23A0537G
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pumps with 750cc, 1000cc, 1500cc, or 2000cc
4-Ball Lowers . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . 11
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 11
Stop the Pump at the Bottom of Its Stroke . . . . 11
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preventive Maintenance Schedule . . . . . . . . . . 12
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mix Tank Volume . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic Power Supply Check . . . . . . . . . . . . . 12
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Changing the TSL . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reassemble the Coupling Adapter and Tie Rods to
the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Viscount I Plus Pumps with 750cc, 1000cc,
1500cc, or 2000cc 4-Ball Lowers . . . . . . . . 18
Viscount II Pumps with 2000cc 4-Ball Lower . . . 19
Viscount II Pumps with 3000cc or
4000 cc 4-Ball Lowers . . . . . . . . . . . . . . . . . 20
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Motor Mounting Hole Diagrams . . . . . . . . . . . . . . 22
Mounting Stand Hole Layouts . . . . . . . . . . . . . . . 22
255143 Wall Mount Bracket . . . . . . . . . . . . . . . . . . 23
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
750, 1000, 1500, and 2000cc Pumps with
Viscount I Plus Motor . . . . . . . . . . . . . . . . . 24
2000cc Pumps with Viscount II Motor . . . . . . . . 25
3000 and 4000cc Pumps with Viscount II Motor 25
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 26
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 30
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 30
Related Manuals
Part No. Description
308330 Viscount I Plus Hydraulic Motor manual
308048 Viscount II Hydraulic Motor manual
3A0539 4-Ball Lower manual (750cc, 1000cc,
1500cc, and 2000cc)
3A0540 4-Ball Lower manual (3000cc and 4000cc)

Models
3A0537G 3
Models
Pumps with 750cc, 1000cc, 1500cc, or 2000cc 4-Ball Lowers
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
24E322 A 450 (3.1, 31.0) 750cc Viscount I Plus npt cst Chromex
™
Nitride
24E323 A 450 (3.1, 31.0) 750cc Viscount I Plus tri-clamp sst Chromex Chrome
24E324 A 450 (3.1, 31.0) 750cc Viscount I Plus tri-clamp sst Chromex MaxLife
®
24E485 A 450 (3.1, 31.0) 750cc Viscount I Plus npt sst Chromex Chrome
24E486 A 450 (3.1, 31.0) 750cc Viscount I Plus npt sst Chromex MaxLife
24E325 A300 (2.1, 21.0) 1000cc Viscount I Plus npt cst Chromex Chrome
24E326 A300 (2.1, 21.0) 1000cc Viscount I Plus tri-clamp sst Chromex Chrome
24E327 A300 (2.1, 21.0) 1000cc Viscount I Plus tri-clamp sst Chromex MaxLife
24E487 A300 (2.1, 21.0) 1000cc Viscount I Plus npt sst Chromex Chrome
24E488 A300 (2.1, 21.0) 1000cc Viscount I Plus npt sst Chromex MaxLife
24E328 A 225 (1.6, 16.0) 1500cc Viscount I Plus npt cst Chromex Chrome
24E329 A 225 (1.6, 16.0) 1500cc Viscount I Plus tri-clamp sst Chromex Chrome
24E330 A 225 (1.6, 16.0) 1500cc Viscount I Plus tri-clamp sst Chromex MaxLife
24E489 A 225 (1.6, 16.0) 1500cc Viscount I Plus npt sst Chromex Chrome
24E490 A 225 (1.6, 16.0) 1500cc Viscount I Plus npt sst Chromex MaxLife
24E331 A167 (1.2, 12.0) 2000cc Viscount I Plus npt cst Chromex Chrome
24E332 A167 (1.2, 12.0) 2000cc Viscount I Plus tri-clamp sst Chromex Chrome
24E333 A167 (1.2, 12.0) 2000cc Viscount I Plus tri-clamp sst Chromex MaxLife
24E491 A167 (1.2, 12.0) 2000cc Viscount I Plus npt sst Chromex Chrome
24E492 A167 (1.2, 12.0) 2000cc Viscount I Plus npt sst Chromex MaxLife
24E334 A 460 (3.2, 32.0) 2000cc Viscount II npt cst Chromex Chrome
24E335 A 460 (3.2, 32.0) 2000cc Viscount II tri-clamp sst Chromex Chrome
24E336 A 460 (3.2, 32.0) 2000cc Viscount II tri-clamp sst Chromex MaxLife
24E493 A 460 (3.2, 32.0) 2000cc Viscount II npt sst Chromex Chrome
24E494 A 460 (3.2, 32.0) 2000cc Viscount II npt sst Chromex MaxLife
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 Chromex MaxLife
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 Chromex MaxLife

Warnings
43A0537G
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.
WARNINGWARNINGWARNING
WARNING
PERIGO DE FOGO E EXPLOSÃO
Os vapores inflamáveis na área de trabalho, tais como os provenientes de solventes e tintas, podem
inflamar-se ou explodir. Para ajudar a evitar incêndio e explosão:
• Utilize o equipamento apenas em áreas bem ventiladas;
• Elimine todas as fontes de ignição, como, por exemplo, luzes piloto, cigarros, luzes elétricas portáteis
e plásticos de proteção (potencial arco estático).
• Mantenha a área de trabalho sem detritos, incluindo solvente, panos e gasolina;
• Não ligue nem desligue cabos de alimentação ou interruptores, na presença de vapores inflamáveis;
• Ligue à terra todo o equipamento na área de trabalho. Consulte as instruções de Ligação à terra .
• Utilize apenas tubos flexíveis com ligação à terra;
• Segure a pistola firmemente apoiando-a na parede do balde em contacto com a terra, quando estiver
a descarregar para dentro do mesmo;
• Se ocorrerem faíscas de estática ou se sentir um choque elétrico, interrompa a utilização imediatamente.
Não utilize o equipamento até identificar e corrigir o problema.
• Tenha sempre um extintor operacional na área de trabalho.
A carga estática pode-se acumular nas peças plásticas durante a limpeza e pode disparar e inflamar
vapores inflamáveis. Para ajudar a evitar incêndio e explosão:
• Limpe as peças plásticas apenas em áreas bem ventiladas.
• Não limpe com um pano seco.
• Não opere pistolas eletrostáticas numa área de trabalho de equipamento.
PERIGO DE EQUIPAMENTO PRESSURIZADO
O produto proveniente da pistola/pistola de distribuição, fugas ou componentes danificados poderá entrar
em contacto com os olhos ou com a pele e provocar ferimentos extremamente graves.
• Siga o Procedimento de Descompressão neste manual, quando parar de pintar e antes de dar
início aos procedimentos de limpeza, verificação ou manutenção.
• Aperte todas as ligações relativas ao produto antes de utilizar o equipamento.
• Verifique diariamente todos os tubos e uniões. Substitua imediatamente as peças gastas ou danificadas.
PERIGO EMERGENTE DE PRODUTOS OU VAPORES TÓXICOS
Os líquidos ou vapores tóxicos podem provocar lesões graves ou morte se entrarem em contacto com os
olhos e a pele, ou se forem inalados ou engolidos.
• Leia as folhas de dados de segurança do material (MSDS) para conhecer os perigos específicos dos
líquidos que está a utilizar.
• Armazene os líquidos perigosos em recipientes aprovados e elimine-os em conformidade com as
diretrizes aplicáveis.

Warnings
3A0537G 5
EQUIPAMENTO DE PROTECÇÃO PESSOAL
Utilize equipamento de proteção adequado ao usar o equipamento ou se estiver na área de funcionamento
do mesmo. O equipamento protege-o de lesões graves, tais como lesões oculares, perda de audição,
inalação de vapores tóxicos e queimaduras. Este equipamento inclui, mas não é limitado a:
• Proteção para os olhos e ouvidos.
• Respiradores, roupa protetora e luvas, tal como recomendado pelo fabricante do líquido e solvente.
PERIGO DE MÁ UTILIZAÇÃO DO EQUIPAMENTO
A utilização incorreta do equipamento poderá resultar em ferimentos graves ou morte.
• Não utilize a unidade se estiver cansado ou sob a influência de drogas ou de álcool.
• Não exceda a pressão de trabalho ou o nível de temperatura máximo do componente do sistema com
a classificação mais baixa. Consulte a Dados Técnicos em todos os manuais do equipamento.
• Utilize líquidos e solventes compatíveis com as peças do equipamento em contacto com o líquido.
Consulte a Dados Técnicos em todos os manuais do equipamento. Leia as advertências dos
fabricantes do líquido e do solvente. Para obter informações completas relativas ao material que utiliza,
solicite a folha de dados de segurança do material (MSDS) ao distribuidor ou ao revendedor.
• Não abandone a área de trabalho enquanto o equipamento se encontrar energizado ou sob pressão.
Desligue todo o equipamento e siga o Procedimento de Descompressão quando o equipamento
não está a ser utilizado.
• Verifique diariamente o equipamento. As peças danificadas ou com desgaste devem ser imediatamente
reparadas ou substituídas apenas por peças genuínas do fabricante.
• Não altere nem modifique este equipamento.
• Utilize o equipamento apenas para o fim a que se destina. Solicite informações ao seu distribuidor.
• Afaste os tubos flexíveis e cabos de áreas com movimento, pontas afiadas, peças em movimento e
superfícies quentes.
• Não dê nós nem dobre os tubos flexíveis, nem os utilize para puxar o equipamento.
• Mantenha as crianças e os animais afastados da área de trabalho.
• Cumpra todas as normas de segurança aplicáveis.
PERIGO RESULTANTE DE PEÇAS EM MOVIMENTO
As peças em movimento podem entalar ou amputar os dedos e outras partes do corpo.
• Mantenha-se afastado das peças em movimento.
• Não utilize o equipamento tendo removido as respetivas proteções e coberturas.
• O equipamento sob pressão pode começar a funcionar sem aviso. Antes de efetuar ações de verificação,
deslocação ou assistência no equipamento, siga o Procedimento de Descompressão e desligue
todas as fontes de alimentação.
WARNINGWARNINGWARNING
WARNING

Installation
63A0537G
Installation
Grounding
Pump: use a ground wire and clamp. See F IG . 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.
F
IG . 1 Ground Wire
TI15854a
Z
Y
W

Installation
3A0537G 7
Stand Mount
Mount the pump in the accessory pump stand (B). Use
Part No. 253692 Stand for 750, 1000, 1500, and 2000cc
Pumps (see F
IG . 2, page 9) and Part No. 218742 Stand
for 3000 and 4000cc Pumps (see F
IG . 3, page 10).
See Mounting Stand Hole Layouts on page 22.
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 23.
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 12.

Installation
83A0537G
Accessories
Install the following accessories in the order shown in
F
IG . 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 F IG . 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
3A0537G 9
Key:
A Mix Tank
B 253692 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)
F IG . 2. Typical Installation for 750, 1000, 1500, and 2000cc Pumps (Viscount I Plus Motor Shown)
TI15855a
KL
F
A
U
E
BD
G
D
E
U
D
R
N P S
J
C
MT
Y

Installation
10 3A0537G
Key:
A Mix Tank
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)
F IG . 3. 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
3A0537G 11
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 F
IG . 4 on page 13.
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 Pressure Relief Procedure, page 11.
Always flush the pump before the fluid dries on the dis-
placement rod. See Flushing on page 12.
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.

Maintenance
12 3A0537G
Maintenance
Preventive Maintenance
Schedule
The operating conditions of your particular system
determine how often maintenance is required. Establish
a preventive maintenance schedule by recording when
and what kind of maintenance is needed, and then
determine a regular schedule for checking your system.
Your maintenance schedule should include the follow-
ing:
Flushing
• Flush before changing colors, before fluid can dry in
the equipment, at the end of the day, before storing,
and before repairing equipment.
• Flush at the lowest pressure possible. Check con-
nectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
Mix Tank Volume
Don't let the mix tank run dry. When the tank is empty,
the pump demands more power as it tries to suck in
some fluid. This causes the pump to run too fast, which
can seriously damage the pump.
Hydraulic Power Supply Check
Carefully follow the hydraulic power supply manufac-
turer's recommendations on reservoir and filter cleaning,
and periodic changes of hydraulic fluid.
Stall Test
Perform a stall test periodically to ensure the piston seal
is in good working condition and prevent system over-
pressurization:
Close the fluid shutoff valve (D) closest to the pump on
the downstroke and be sure that the pump stalls. Open
the fluid shutoff valve to restart the pump. Close the fluid
shutoff valve (D) closest to the pump on the upstroke
and be sure that the pump stalls.
Stop the pump on the downstroke, before the air motor
changes over.
NOTICE
Do not allow the pump to run quickly for a long period
of time as this may damage the packings.
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.

Maintenance
3A0537G 13
Changing the TSL
Check the condition of the TSL and the level in the res-
ervoir every week, minimum. TSL should be changed at
least every month.
Part No. 206995 Throat Seal Liquid (TSL) carries resi-
due from the pump rod into the reservoir. Discoloration
of the TSL fluid is to be expected during normal opera-
tion. After some time the TSL will thicken and darken,
and must be replaced. Thick, dirty TSL will not pump
through the lines and will harden in the pump wet-cup.
How long TSL lasts depends on which chemicals are
used, how much is used, what pressure, and condition
of the pump seal and rod.
A drop in the level of TSL in the reservoir indicates that
the throat packings are starting to wear. Add TSL to the
reservoir and keep the level above the Minimum fill line.
Monitor the usage and condition of the TSL. If pumped
material bypasses the throat packings and enters the
TSL reservoir, replace the packings.
To change the TSL:
1. Shut off the pump.
2. Remove and empty the reservoir bottle. Clean any
residue.
3. Clean screen (Z) of inlet check valve (VI). If check
valves are not sealing and dirty TSL is getting into
the wet-cup, replace the check valves (VI, VO). See
F
IG . 4.
4. Fill the reservoir to the Maximum fill line with Throat
Seal Liquid (TSL).
5. Run pump. Each time pump rod reaches bottom of
stroke, check that some TSL is pumped from reser-
voir through wet-cup and back to reservoir.
To avoid the buildup of static charge, do not rub the
plastic bottle with a dry cloth while it is attached to the
pump. Remove the bottle to clean, if needed.
F IG . 4. Cutaway of TSL Reservoir, and Fill Lines
TI15853b
VO
VI
TI15857a
Maximum Fill Line
Minimum Fill Line
Z

Troubleshooting
14 3A0537G
Troubleshooting
Problem Cause Solution
Pump output low on both strokes. Restricted hydraulic supply lines. Clear any obstructions; be sure all shutoff
valves are open; increase pressure, but
do not exceed maximum working pres-
sure.
Exhausted fluid supply. Refill and reprime pump.
Clogged fluid outlet line, valves, etc. Clear.
Worn piston packing. Replace. See lower manual.
Pump output low on only one stroke. Held open or worn ball check valves. Check and repair.
Worn piston packings. Replace. See lower manual.
No output. Improperly installed ball check valves. Check and repair.
Pump operates erratically. Exhausted fluid supply. Refill and reprime pump.
Held open or worn ball check valves. Check and repair.
Worn piston packing. Replace. See lower manual.
Excessive hydraulic fluid supply pres-
sure to motor.
See motor manual.
Pump will not operate. Restricted hydraulic supply lines. Clear any obstructions; be sure all shut
off valves are open; increase pressure,
but do not exceed maximum working
pressure.
Exhausted fluid supply. Refill and reprime pump.
Clogged fluid outlet line, valves, etc. Clear.
Damaged hydraulic motor. See motor manual.
Fluid dried on piston rod. Disassemble and clean pump. See lower
manual. In future, stop pump at bottom of
stroke.

Repair
3A0537G 15
Repair
Disassembly
NOTE: The 3000 and 4000cc pumps are easiest to
repair when left in the Part No. 218742 accessory pump
stand and disassembled as instructed in the lower man-
ual. For repair at a remote location, have another pump
stand available.
1. Relieve the pressure, see Pressure Relief Proce-
dure page 11.
2. Disconnect the hoses from the lower and plug the
ends to prevent fluid contamination.
3. See F
IG . 5. Remove the 2-piece shield (122) by
inserting a screwdriver straight into the slot, and
using it as a lever to release the tab. Repeat for all
tabs. Do not use the screwdriver to pry the shields
apart.
4. Loosen the coupling nut (105) and remove the col-
lars (106). Remove the coupling nut from the piston
rod (R). Unscrew the locknuts (104) from the tie
rods (103). Separate the motor (101) and lower
(102). See F
IG . 6.
5. To repair the air motor or lower, see the separate
manuals listed under Related Manuals on page 2.
Reassembly
NOTE: If the coupling adapter (108) and tie rods (103)
have been disassembled from the motor, see Reas-
semble the Coupling Adapter and Tie Rods to the
Motor on page 17.
1. See F
IG . 6. Assemble the coupling nut (105) to the
piston rod (R).
2. Orient the lower (102) to the motor (101). Position
the lower on the tie rods (103). Lubricate the
threads of the tie rods. Screw the tie rod locknuts
(104) onto the tie rods. Torque the tie rod locknuts
to 50-55 ft-lb (68-75 N•m).
3. Insert the collars (106) into the coupling nut (105).
a.
750, 1000, 1500, and 2000cc Pumps: Tighten
the coupling nut onto the coupling adapter (108)
and torque to 90-100 ft-lb (122-135 N•m).
b.
3000 and 4000cc Pumps: Tighten the coupling
nut onto the motor shaft (S) and torque to 150
ft-lb (203 N•m).
4. See F
IG . 5. Install the shields (122) by engaging the
bottom lips with the groove in the wet-cup cap (C).
Snap the two shields together.
5. Flush and test the pump before reinstalling it in the
system. Connect hoses and flush the pump. While it
is pressurized, check for smooth operation and
leaks. Adjust or repair as necessary before reinstall-
ing in the system. Reconnect the pump ground wire
before operating.
F IG . 5. Disassembly and Reassembly of the Shields
ti15759a
Shield Disassembly
ti15770a
ti15757a
ti15758a
Shield

Repair
16 3A0537G
F IG . 6. Reassembly
Torque to 90-100 ft-lb (122-135 N•m).
Torque to 50-55 ft-lb (68-75 N•m).
Lubricate threads.
Torque to 75-80 ft-lb (102-109 N•m).
Torque to 150 ft-lb (203 N•m).
Torque to 15-17 ft-lb (20-23 N•m).
1
2
3
4
5
6
1
4
2
3
103
TI15610a
106
105
104
101
102
101
102
103
104
TI15602a
107
106
108
105
109
110
111
Part of 101
103
TI15599a
106
108
105
104
112
109
101
102
111
R
R
R
S
S
5
6
2
3
2
3
2
2
2
1
2
Viscount II Pump
with 4000cc 4-Ball
Lower
Viscount II Pump
with 2000cc 4-Ball
Lower
Viscount I Plus
Pump with
1000cc 4-Ball
Lower
122
122
122

Repair
3A0537G 17
Reassemble the Coupling
Adapter and Tie Rods to the
Motor
NOTE: Use this procedure only if the coupling adapter
(108) and tie rods (103) have been disassembled from
the motor, to ensure proper alignment of the motor shaft
to the piston rod.
NOTE: 3000 and 4000cc Pumps do not have a coupling
adapter (108) or a mounting plate (111).
1.
750, 1000, 1500, and 2000cc Pumps only: Loosen,
but do not remove, the screws holding the mounting
plate (111) to the motor (101). See F
IG . 6.
2. Install the tie rods (103).
a.
750, 1000, 1500, and 2000cc Viscount I Plus
Pumps:
Screw the tie rods (103) through the
mounting plate (111) and into the threaded
holes in the base of the motor. Torque to 50-55
ft-lb (68-75 N•m).
b.
750, 1000, 1500, and 2000cc Viscount II
Pumps:
Screw the tie rods (103) into the mount-
ing plate (111) and torque to 50-55 ft-lb (68-75
N•m).
c.
3000 and 4000cc Pumps: Screw the tie rods
(103) into the base of the motor and torque to
50-55 ft-lb (68-75 N•m).
3. Fill the cavity in the bottom of the motor shaft with
grease.
4.
750, 1000, 1500, and 2000cc Pumps only: Install
the coupling adapter (108) as follows.
a.
Viscount I Plus motors: Screw the coupling
adapter (108) into the motor shaft until the pin
holes align. Install the pin (107) in the first hole
from the end of the coupling.
b.
Viscount II motors: Slide the adapter nut (112)
onto the adapter (108). Screw the nut (112)
onto the motor shaft (S) and torque to 75-80
ft-lb (102-109 N•m).
5. Orient the lower (102) to the motor (101). Position
the lower on the tie rods (103). Lubricate the
threads of the tie rods. Loosely screw the tie rod
locknuts (104) onto the tie rods.
6. 750, 1000, 1500, and 2000cc Pumps only: Tighten
the mounting plate screws as follows.
a.
Viscount I Plus motors: Torque the screws (109)
to 15-17 ft-lb (20-23 N•m).
b.
Viscount II motors: Torque the screws (109) to
50-55 ft-lb (68-75 N•m).
7. Torque the tie rod locknuts (104) to 50-55 ft-lb
(68-75 N•m).
8. Insert the collars (106) into the coupling nut (105).
a.
750, 1000, 1500, and 2000cc Pumps: Tighten
the coupling nut onto the coupling adapter (108)
and torque to 90-100 ft-lb (122-135 N•m).
b.
3000 and 4000cc Pumps: Tighten the coupling
nut onto the motor shaft (S) and torque to 150
ft-lb (203 N•m).
9. Flush and test the pump before reinstalling it in the
system. Connect hoses and flush the pump. While it
is pressurized, check for smooth operation and
leaks. Adjust or repair as necessary before reinstall-
ing in the system. Reconnect the pump ground wire
before operating.

Parts
18 3A0537G
Parts
Viscount I Plus Pumps with 750cc, 1000cc, 1500cc,
or 2000cc 4-Ball Lowers
Common Parts
Parts that Vary by Model
101
102
103
104
TI15602a
107
106
108
105
109
110
111
Part of 101 122
Ref.
No. Description Part No.
Qty
.
101 MOTOR, Viscount I Plus, see manual
308330
261466 1
102 LOWER, 4-Ball, see manual 3A0539 see tables 1
103 TIE ROD, 14.25 in. (362 mm) between
shoulders
15G924 3
104 NUT, lock, hex; 9/16-12 unc 108683 3
105 NUT, coupling 184059 1
106 COLLAR, coupling 184128 2
107 PIN, cotter 100103 1
108 ADAPTER, coupling 16C373 1
109 SCREW, cap 100001 4
110 WASHER, lock 100214 4
111 PLATE, mounting 16E086 1
122 SHIELD KIT; includes 2 shields 24F252 1
Pump
(see page 3) Lower Size
102
4-Ball Lower
(see manual 3A0539)
24E322
750cc
24F420
24E323 24F415
24E324 24F416
24E485 24F413
24E486 24F414
24E325
1000cc
24F431
24E326 24F426
24E327 24F427
24E487 24F424
24E488 24F425
24E328
1500cc
24F439
24E329 24F434
24E330 24F435
24E489 24F432
24E490 24F433
24E331
2000cc
24F447
24E332 24F441
24E333 24F442
24E491 24F440
24E492 24F443

Parts
3A0537G 19
Viscount II Pumps with 2000cc 4-Ball Lower
Common Parts
Parts that Vary by Model
103
TI15599a
106
108
105
104
112
109
101
102
111
122
Ref.
No. Description Part No.
Qty
.
101 MOTOR, Viscount II, see manual
308048
223646 1
102 LOWER, 4-Ball, see manual 3A0539 see table 1
103 TIE ROD, 14.25 in. (362 mm) between
shoulders
15G924 3
104 NUT, lock, hex; 9/16-12 unc 108683 3
105 NUT, coupling 184059 1
106 COLLAR, coupling 184128 2
108 ADAPTER, coupling 15K736 1
109 SCREW, cap, socket hd C19789 3
111 PLATE, mounting 120558 1
112 NUT, adapter 183079 1
122 SHIELD KIT; includes 2 shields 24F252 1
Pump
(see page 3) Lower Size
102
4-Ball Lower
(see manual 3A0539)
24E334
2000cc
24F447
24E335 24F441
24E336 24F442
24E493 24F440
24E494 24F443

Parts
20 3A0537G
Viscount II Pumps with 3000cc or 4000 cc 4-Ball Lowers
Common Parts
Parts that Vary by Model
103
TI15610a
106
105
104
101
102
122
Ref.
No. Description Part No.
Qty
.
101 MOTOR, Viscount II, see manual
308048
223646 1
102 LOWER, 4-Ball, see manual 3A0540 see table 1
103 TIE ROD, 12.72 in. (323 mm) between
shoulders
180487 3
104 NUT, lock, hex; 9/16-12 unc 102216 3
105 NUT, coupling 186925 1
106 COLLAR, coupling 184129 2
122 SHIELD KIT; includes 2 shields 24F255 1
Pump
(see page 3) Lower Size
102
4-Ball Lower
(see manual 3A0540)
24E337
3000cc
24F450
24E338 24F448
24E339 24F449
24E340
4000cc
24F453
24E341 24F451
24E342 24F452