Graco Dyna-Mite 190 Datasheet

Instructions–Parts List
308302K
ENG
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
8.5:1 RATIO STAINLESS STEEL
Dyna-Mitet190 Pump
Used for precision dispense of viscous materials from small
containers. For professional use only.
Not approved for use in European explosive atmosphere locations.
6.0 MPa, 60 bar (850 psi) Maximum Fluid Working Pressure
0.7 MPa, 7 bar (100 psi) Maximum Air Inlet Pressure
Part No. 235870, Series C
Does not include Pump and Ram
Part No. 235871, Series C
Includes Pump and Ram
Wiper Plates (order separately)
Model 224908, Series A
3 kilogram (1 gallon) size
Model 224923, Series B
1 kilogram (1 quart) size

2308302
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
INSTRUCTIONS
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 uncertain about usage, 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. Refer to the
Technical Data on page 26 for the maximum working pressure of this equipment.
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 exceed the maximum working pressure of the lowest rated system component. This equip-
ment has a 6.0 MPa, 60 bar (850 psi) maximum working pressure.
DDo not 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 82_C (180_F) or below –40_C (–40_F).
DWear hearing protection when operating this equipment.
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.

3308302
WARNING
PRESSURIZED EQUIPMENT HAZARD
Spray from the gun/valve, hose leaks, or ruptured components can splash fluid in the eyes or on the
skin can also cause serious injury.
DDo not point the gun/valve at anyone or at any part of the body.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DFollow the Pressure Relief Procedure on page 10 whenever you: are instructed to relieve pres-
sure; stop dispensing; clean, check, or service the equipment; and install or clean the nozzle.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
MOVING PARTS HAZARD
Moving parts, such as the priming piston, can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 10 to prevent the
equipment from starting unexpectedly.
DKeep hands and fingers away from the priming piston during operation and whenever the pump is
charged with air.
DKeep your hands away from the wiper plate and the lip of the fluid container while the ram is oper-
ating.
DDo not place your fingers into the air motor coupling cavity while the pump is operating.
DDo not shut off the air supply to the ram while it is being raised. Doing so will cause the pump to fall
uncontrolled to the bottom.

4308302
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.
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 dis-
pensing 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 dispensed.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DElectrically disconnect all equipment in the dispensing area.
DExtinguish all open flames or pilot lights in the dispensing area.
DDo not smoke in the dispensing area.
DDo not turn on or off any light switch in the dispensing area while operating or if fumes are present.
DDo not operate a gasoline engine in the dispensing 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.

5308302
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.
To reduce the risk of static sparking, ground the pump.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment. Be
sure to ground all of this dispensing equipment.
1. Pump: unscrew the green grounding screw (W)
and washer (X), located on the ram base (Z).
Install a 1.5 mm2(12 ga) minimum ground wire (Y)
and secure with the screw and washer. Connect
the other end of the ground wire to a true earth
ground. See Fig. 1.
2. Fluid hoses: use only grounded fluid hoses.
3. Dispensing valve: obtain grounding through con-
nection to a properly grounded fluid hose and
pump.
4. Fluid supply container: obtain grounding by secur-
ing the container to the ram base with the clamps.
5. Air compressor: according to local code.
6. To maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
dispense valve firmly to the side of a grounded
metal pail, ten trigger the valve.
Fig. 1
W
X
Y
Z
02102

6308302
Installation
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
Parts Drawing.
If you supply your own accessories, be sure they are
adequately sized and pressure-rated to meet the
system’s requirements.
Contact your Graco distributor for assistance in de-
signing a system to suit your particular needs.
Pump Location and Set-Up
1. Place the unit on a hard, level surface. Check that
the unit is level in all directions. Refer to Dimen-
sions on page 28 to ensure that there is sufficient
overhead clearance for the pump when the ram is
fully raised. Leave room on both sides so the air
regulators will be easily accessible.
2. Read the section System Components and
Accessories on page 9. Connect an air supply
hose to the 1/4 npt(f) main air inlet fitting (57). See
Fig. 2.
3. Unpack the wiper plate (P). Back out the screws
(302) so they will clear the pump intake housing
(11). Raise the ram by setting the ram director
valve switch (36) to the UP position and increasing
the setting of the ram air regulator (27b).
4. Place the wiper plate (P) on a 2 in. thick x 4 in.
wide block of wood. Center the wiper plate and the
wood block on the base, under the pump intake
housing (11).
5. Set the ram air regulator (27b) to zero. Set the ram
director valve switch (36) to the DOWN position.
As the ram unit slowly falls, guide the pump intake
housing (11) into the wiper plate (P).
6. Set the ram air regulator (27b) to 0.07 MPa, 0.7
bar (10 psi). Push down on the pump to install the
wiper plate (P) onto the intake housing (11). Se-
cure the wiper plate to the pump with the two
screws (302).
7. Connect the 660 mm (26 in.) air line tube (76) from
the connector (37) at the air assist valve (18) to
the connector (310) at the wiper plate (P). Refer to
Connecting and Disconnecting Tubes.
Connecting and Disconnecting Tubes
Connection
1. Grasp the tube, then slowly push it straight into the
fitting until it stops.
2. Be sure that the tube is securely connected, and
will not pull out when air pressure is applied. To
check, pull back gently on the tube to ensure that it
will not pull out.
Disconnection
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
1. Relieve the pressure.
2. Push evenly on the fitting’s red release button.
3. While holding the release button in, pull the tube
out of the fitting.
4. To reuse the tubing, cut off the previously connec-
tion portion at 90_, being careful not to damage
the outer diameter of the tube. Use of a tube cutter
is recommended. The fitting will leak if the tubing is
not cut at 90_.

7308302
Installation
Fig. 2
1Order Wiper Plate (P) separately.
KEY
P Wiper Plate Assembly
1 Pump
8 Bleed-Type Master Air Valve
11 Pump Fluid Intake Housing
18 Air Assist Valve (Push button)
25 Pump Bleeder Valve
27a Pump Air Regulator
27b Ram Air Regulator
28 Fluid Outlet Fitting
37 Air Assist Valve Connector
57 Air Inlet
76 Air Line to Wiper Plate
302 Capscrews
310 Wiper Plate Connector
1
1
76
57
27b
37
18
310
25
30211
P
28
27a
8
02093B

8308302
Notes

9308302
Installation
System Accessories (See Fig. 2)
WARNING
Two required safety devices are supplied with your
pump: a bleed-type master air valve (8) and a
pump bleeder valve (25). These devices help
reduce the risk of serious injury, including splashing
in the eyes or on the skin, and injury from moving
parts if you are adjusting or repairing the pump.
The bleed-type master air valve relieves air trapped
between this valve and the pump after the air is
shut off. Trapped air can cause the pump to cycle
unexpectedly. The valve is located close to the
pump, downstream from the pump air regulator.
The pump bleeder valve assists in relieving fluid
pressure in the displacement pump, hose, and
dispensing valve. Triggering the dispensing valve to
relieve pressure may not be sufficient.
Supplied Components
The following components are supplied with your
pump.
DThe bleed-type master air valve (8) is supplied
with your system to relieve air trapped between it
and the air motor when the valve is closed (see the
WARNING above).
DThe pump air regulator (27a) controls pump
speed and outlet pressure by adjusting the air
pressure to the pump. The regulator is located
upstream from the bleed-type master air valve.
DThe ram air regulator (27b) controls ram speed by
adjusting the air pressure to the ram, and also
controls the pressure exerted by the wiper plate on
the fluid.
DThe pump bleeder valve (25) is supplied in your
system to relieve fluid pressure in the displacement
pump, hose, and dispensing valve (see the WARN-
ING at left). Be sure the drain hole in the valve is
pointing down. This valve is also used to bleed air
from the pump when priming.
Air Line
Connect an air supply hose to the 1/4 npt(f) main air
inlet fitting (57). Install an air line filter and lubricator in
the main air line. In the main air line, upstream from all
other air line accessories, install a second bleed-type
master air valve to shut off all air to the system and to
isolate the accessories for servicing.
Fluid Line
Connect a fluid hose to the fluid outlet fitting (28).
Connect a suitable dispensing valve to the free end of
the hose.

10 308302
Operation
Pressure Relief Procedure
WARNING
PRESSURIZED EQUIPMENT HAZARD
The system pressure must be manually relieved to
prevent the system from starting or spraying acci-
dentally. To reduce the risk of an injury from acci-
dental spray from the gun, splashing fluid, or
moving parts, follow the Pressure Relief Proce-
dure whenever you:
Dare instructed to relieve the pressure,
Dstop spraying,
Dcheck or service any of the system equipment,
Dor install or clean the spray nozzle.
1. Shut off the dispensing valve.
2. Shut off the bleed-type master air valve (required
in your system), on the main air line.
3. Close the bleed-type master air valve (supplied
with your pump).
4. Trigger the dispensing valve to relieve pressure.
If you suspect that the dispensing valve, nozzle, or
hose is completely clogged, or that pressure has not
been fully relieved after following the steps above, very
slowly open the pump bleeder valve, having a contain-
er ready to catch the drainage. Leave the pump bleed-
er valve open until you are ready to dispense again.
Very slowly loosen the hose end coupling and relieve
pressure gradually, then loosen completely. Now clear
the nozzle or hose.
WARNING
Keep hands and fingers away from the priming
piston and pump intake during operation and
whenever the pump is charged with air. During
operation, the priming piston extends beyond the
intake housing to pull material into the pump, and
can severely injure or amputate a hand or finger
caught between it and the intake housing. Always
follow the Pressure Relief Procedure at left
before clearing, cleaning, flushing, or servicing any
part of the pump.
The air motor piston and fluid piston (located inside
the air motor cylinder and coupling) also move
when air is supplied to the motor. Do not place your
hand or fingers into the air motor coupling cavity
while the pump is operating.
As the ram is raised and lowered, the wiper plate,
ram tubes, and pump mounting bracket move. To
reduce the risk of pinching or amputation of fingers,
keep you hands away from the wiper plate, lip of
the fluid can, pump bracket, and ram tubes while
the pump is operating.
To reduce the risk of serious injury and damage to
equipment, do not shut off the air supply to the ram
when the ram is raised. Doing so will cause the
pump to fall uncontrolled to the bottom.

11308302
Operation
Starting and Adjusting the Ram
1. Refer to Fig. 3. Be sure all air regulators and
bleed-type air valves are closed.
2. Open the air valve in the main air line and set the
ram air regulator (27b) to 200 kPa, 2 bar (28 psi).
Set the ram director valve switch (36) to the UP
position and let the ram rise to its full height. To
change the speed at which the ram raises and
lowers, adjust the air regulator to increase or
decrease the air volume.
3. Check that the fluid can is not dented or out of
shape, which will damage the wiper plate and
cause leakage around the wiper. Cut off the top of
the fluid can with the can opener, or remove the
bottom of the can. Be sure that the edge is free of
burrs, which will damage the wiper plate. If neces-
sary, bend the edge back with a pliers so the wiper
plate will enter the can easily. Lubricate the wiper
ring (305) to help the plate enter the can easily.
4. Set a can of fluid on the ram base, centering it
under the wiper plate (P). If the can has a welded
seam, position it with the seam facing the rear of
the pump.
5. Loosen the wiper plate bleed valve (303) enough
to allow air trapped under the wiper plate to es-
cape. With your hands away from the lip of the can
and the wiper plate, set the director valve switch
(36) to the DOWN position and lower the ram until
the wiper plate enter the can. Reduce the air
pressure when the plate enters the can.
NOTE: If the wiper plate does not enter the can easily,
increase the ram pressure; once it enters the can,
immediately reduce the pressure.
6. Continue to lower the ram until fluid appears at the
wiper plate vent hole. Tighten the wiper plate bleed
valve (303) securely. See Fig. 3.
7. Clamp the can in place with the clamps (24) and
wing screws (39), being sure the clamp catches
the lip of the can.
Priming the Pump and Pumping Fluid
1. Be sure the pump air regulator (27a) is closed.
Then set the ram air regulator (27b) to be about
150 kPa, 1.5 bar (22 psi). Set the director valve
switch (36) to DOWN.
2. Open the bleed-type master air valve (8). Set the
pump air regulator (27a) to 200 kPa, 2 bar (28 psi).
3. Open the pump bleeder valve (25) to allow air to
bleed from the pump. When the pump is fully
primed, close the valve.
4. Keep the director valve switch (36) in the DOWN
position while the pump is operating.
NOTE: Adjust the air pressure to the ram as needed,
but do not increase it to a level where fluid is forced
past the wiper plate.

12 308302
Operation
Fig. 3
1Order Wiper Plate (P) separately.
See page 23.
KEY
P Wiper Plate Assembly
1 Pump
8 Bleed-Type Master Air Valve
18 Air Assist Valve (Push button)
24 Clamps
25 Pump Bleeder Valve
27a Pump Air Regulator
27b Ram Air Regulator
28 Fluid Outlet Fitting
36 Ram Director Valve
76 Air Tube
39 Clamp Wing Screws
302 Wiper Plate Screws
303 Wiper Bleed Valve
305 Wiper Plate Ring
1
1
27b
18
36
305
25
P
303
28
27a
8
39 24
02093B
302
76

13308302
Operation
Changing Fluid Cans
1. Stop the pump. Close the bleed-type master air
valve (8), but leave air pressure on to the ram. Set
the ram air regulator (27b) to below 210 kPa, 2.1
bar (30 psi). Open the dispensing valve and relieve
all fluid pressure in the system.
2. Set the director valve switch (36) to UP.
3. Push in the air assist valve (18) and hold it in until
the wiper plate clears the top of the can.
CAUTION
If the fluid has set up and the wiper plate (P) is stuck
in the can, do not increase the setting of the ram air
regulator (27b) to remove the plate. Excessive
pressure in the can may cause the can to rupture. If
you cannot pull the can off the plate by hand, loosen
the two screws (302) holding the plate to the pump
(1), disconnect the air tube (76) from the plate, and
remove the can and plate. It may be necessary to
cut the can to remove the plate.
4. Loosen the clamps (24) and remove the empty
can. Set the full can on the ram base and position
it under the wiper plate. If the can has a welded
seam, position it with the seam facing the rear of
the pump.
5. Lower the ram and adjust the position of the can
relative to the wiper plate, as explained under
Starting and Adjusting the Ram on page 11.
Clamp the can in place.
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 10.
1. Always flush the pump with a compatible solvent
before fluid dries in the pump.
2. Set the director valve switch (36) to DOWN. Allow
the ram to go to the lowest position.
3. Shut off the air supply to the ram and pump and
relieve the pressure.

14 308302
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
Before servicing this equipment always make sure to
Relieve the Pressure.
Check all possible problems and solutions before
disassembling the pump.
Problem Cause Solution
Pump does not operate Restricted air line, clogged air pas-
sages, or inadequate air supply
Clear; see Technical Data on page
26.
Main air valve is closed Open valve.
Air regulator malfunction Repair or replace.
Dirty or worn air motor parts; air mo-
tor leak.
Clean and overhaul air motor. See
page 16.
Obstructed fluid hose or dispensing
valve; fluid hose ID is too small.
Increase pump air regulator pressure.
Fluid is too heavy; pump is laboring Clean. See page 16.
Fluid has dried on the fluid piston Clean and overhaul air motor. See
page 16.
Pump operates, but in small
strokes
Dirty or worn air motor parts; air mo-
tor leak.
Clean and overhaul air motor. See
page 16.
Pump operates, but output is low Restricted air line, clogged air pas-
sages, or inadequate air supply
Clear; see Technical Data on page
26.
Dirty or worn air motor parts; air mo-
tor leak.
Clean and overhaul air motor. See
page 16.
Obstructed fluid hose or dispensing
valve; fluid hose ID is too small
Clear*; use hose with larger ID.
Fluid is too heavy; pump is laboring Increase pump air regulator pressure.
Worn intake valve Service. See page 16.
Pump running too fast Exhausted fluid supply Replace or refill can.
pg
Worn intake valve Service. See page 16.
Dirty or worn air motor parts; air mo-
tor leak
Clean and overhaul air motor. See
page 16.
Ram does not move up or down Restricted air line, clogged air pas-
sages, or inadequate air supply
Clear; see Technical Data on page
26.
Main air valve is closed Open valve.
Air regulator malfunction Repair or replace.
Wiper plate is lodged in container Use air assist valve. See page 13.
Pump does not prime Fluid is too heavy Open pump bleeder valve.
Wiper plate leaks Ram pressure is too high Reduce air pressure to ram.
pp
Wiper plate ring is worn Replace.
Leakage past throat packing Worn u-cup packing Replace (wet-cup is not adjustable).
* To determine if the fluid hose or gun is obstructed, relieve the pressure. Disconnect the fluid hose and place a container at the
pump fluid outlet to catch any fluid. Turn on the air just enough to start the pump (about 140–280 kPa, 1.4–2.8 bar [20–40 psi]). If
the pump starts when the air is turned on, the obstruction is in the fluid hose or gun.

15308302
Notes

16 308302
Service
Disassembly (See Fig. 4)
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 10.
NOTE: Repair Kit 223895 is available to repair the air
motor. Parts included in the kit are marked with an
asterisk, for example (103a*). For the best results, use
all the new parts in the kit.
NOTE: Repair Kit 223894 is available to repair the fluid
pump. Parts included in the kit are marked with a
dagger, for example (114†). For the best results, use
all the new parts in the kit.
1. Relieve the pressure. Disconnect all hoses.
Remove the wiper plate. Remove the fluid outlet
elbow (28), noting its position relative to the air
inlet. Remove only the three screws (138) and
lockwashers (141) holding the pump to the mount-
ing bracket (33).
2. Rotate the pump so the bleeder valve (25) is
aligned with the slot in the mounting bracket (33),
and lift the pump straight up through the bracket.
NOTE: Preform step 3 only if the air valve (165) needs
replacement. Otherwise, proceed to step 4.
3. If it is necessary to replace the air valve (165)
unscrew the cylinder cap (101) from the air motor
cylinder (102). Unscrew the two socket screws
holding the air valve (212). Remove the air valve.
CAUTION
Do not immerse the air valve (165) in solvent. To
clean the valve, use a brush and compressed air.
4. Remove the three remaining screws (138) and
washers (141) holding the air motor coupling (105)
to the cylinder (102). Pull the cylinder straight up
off the coupling until the air valve housing (103a)
clears the air motor piston (104).
5. Unscrew the air valve housing (103a) from the
cylinder (102).
6. Remove the pin (144) from the air motor piston
(104) and the fluid piston (106). Unscrew the air
motor piston from the fluid piston, and pull it
straight up out of the air motor coupling (105).
Remove the large o-ring (103d) from the outer
diameter of the air motor piston, and the two small
o-rings (103b) from the inner diameter.
7. Unscrew the air motor coupling (105) from the
cylinder coupling (196). Pull the air motor coupling
straight up until it clears the fluid piston (106).
Remove the o-ring (103c, 103e) from the coupling.
8. Hold the fluid piston (106) steady by inserting a
small screwdriver or punch into the 4 mm diameter
hole (A). Remove the screw (145) and lockwasher
(135) holding the priming piston (115) to the prim-
ing piston rod (110).
9. Pull the priming piston rod (110) and fluid piston
(106) straight up out of the fluid housing (109).
Remove the pin (123), and unscrew the priming
piston rod from the fluid piston.
10. Unscrew the intake valve housing (111) from the
fluid housing (109). Remove the o-ring (161) from
the intake valve housing.
11. Remove the intake valve (114) and valve stop
(112) from the intake valve housing (111).
12. Unscrew the wet-cup/packing nut (107). Remove
the u-cup packing (163) from the throat. Remove
the o-ring (162) from the wet-cup/packing nut.
13. Clean all parts with a solvent compatible with the
fluid you are pumping, and inspect for wear or
damage. Reassemble as explained on page 18.

17308302
Service
Fig. 4
101
165
102
145
135
115
111
110
114{
112
161{
109
163{
162{
107
196
*103b
*103d
104
144
106
123
*103c
103e*
105
141
138
*103a
1
2
Apply thread lubricant.
4
Torque to 35–37 N.m (298–314 in–lb) 5
3
Torque to 8–10 N.m (72–88 in–lb)
Lubricate.Torque to 2–4 N.m (17–33 in–lb)
Torque to 1.7–2.3 N.m (14–20 in–lb)
Lips must face down.
6
7
7
7
7
7
6
6
6
6
6
6
6
6
6
5
4
3
2
2
2
2
3
1
Apply thread adhesive.
8
8
A
TI0262
177
154
211
212

18 308302
Service
Reassembly (See Fig. 5)
NOTE: Lubricate all packings and o-rings with a com-
patible grease before reassembling.
1. Install the u-cup packing (163†) in the throat of the
fluid housing (109), with the lips facing down.
install the o-ring (162†) into the groove above the
bearing of the wet-cup/packing nut (107). Apply
thread lubricant and install the wet-cup/packing nut
in the fluid housing (109). Torque to 35–37 NSm
(298–314 in-lb).
2. Screw the priming piston rod (110) into the fluid
piston (106) until the holes align. Install the pin
(123) in the holes. Carefully slide the assembled
piston and rod down through the wet-cup and fluid
housing.
3. Place the intake valve (114†) onto the seat of the
intake valve housing (111). Insert the valve stop
(112) into the intake valve housing, with the flat
side facing up. Be sure the valve stop (112) seats
on the lip of the intake housing. Lubricate the
o-ring (161†). Bend it into a kidney shape, then
carefully pish it into the inner groove of the intake
valve housing (111), to avoid damaging it.
4. Apply thread lubricant to the lower threads of the
fluid housing (109). Bring the fluid housing and
intake valve housing (111) together, making sure
the priming piston rod (110) passes straight
through the valve stop (112) and intake valve (114)
installed in the housing (111) onto the fluid housing
(109), then torque to 35–37 NSm (298–314 in-lb).
5. Apply lubricant to the threads of the screw (145).
Hold the fluid piston (106) steady by inserting a
small screwdriver or punch into the 4mm diameter
hole (A). Install the priming piston (115) onto the
end of the priming piston rod (110), using the
screw (145) and lockwasher (135). Torque to
1.7–2.3 NSm (14–20 in-lb).
6. Apply lubricant to the top threads of the fluid
housing (109). Screw the air motor coupling (105)
onto the fluid housing, and torque to 35–37 NSm
(298–314 in-lb).
7. Install the large o-ring (103e*) on the outer diame-
ter of the air motor coupling (105), and the small
o-ring (103c*) in the groove on the inner diameter
of the coupling.
8. Install the two small o-rings (103b*) in the grooves
of the inner diameter of the air motor piston (104).
lower the piston through the air motor coupling
(105) so it engages the threads of the fluid piston
(106). Screw the air motor piston onto the fluid
piston, aligning the holes to obtain maximum
threads engagement. Insert the pin (144) in the
holes.
9. Install the large o-ring (103d*) on the outer diame-
ter of the air motor piston (104).
10. Apply adhesive to the threads of the housing
assembly (103a*) and screw the assembly into the
air motor cylinder (102). Torque to 8–10 NSm
(72–88 in-lb). Apply lubricant to the outer diameter
of the air valve housing assembly (103a) and the
inner diameter of the air motor cylinder (102).
11. Lower the air motor cylinder (102) onto the air
motor coupling (105). Align the air inlet with the
fluid outlet, as was noted in step 1 under Disas-
sembly. The air valve housing assembly (103a)
will slide down into the air motor piston (104).
Secure the cylinder to the coupling with three
screws (138) and washers (141). Torque the
screws to 2–4 NSm (17–33 in-lb).
12. If it was necessary to replace the air valve (165)
align and install the new air valve on the top of the
air motor cylinder (102), as shown in Fig. 4. Install
the two mounting screws and washers and torque
to 2–4 NSm (17–33 in-lb). Lubricate the upper
threads of the air motor cylinder (102). Screw the
cylinder cap (101) onto the cylinder.
13. Lower the pump through the mounting bracket
(33). Orient it in the correct direction and secure to
the bracket using the three screws (138) and
washers (141). Torque the screws to 2–4 NSm
(17–33 in-lb). Reinstall the fluid outlet fitting (28).
14. Reinstall the wiper plate assembly on the fluid
intake housing (111). Secure with the two cap-
screws (302). Reconnect all hoses and return the
pump to service.

19308302
Service
Fig. 5
101
212
102
145
135
115
111
110
114{
112
161{
109
163{
162{
107
196
*103b
*103d
104
144
106
123
*103c
103e*
105
141
138
*103a
1
2
Apply thread lubricant.
4
Torque to 35–37 N.m (298–314 in–lb) 5
3
Torque to 8–10 N.m (72–88 in–lb)
Lubricate.Torque to 2–4 N.m (17–33 in–lb)
Torque to 1.7–2.3 N.m (14–20 in–lb)
Lips must face down.
6
7
7
7
7
7
6
6
6
6
6
6
6
6
6
5
4
3
2
2
2
2
3
1
Apply thread adhesive.
8
8
A
TI0262
165
211
154
177

20 308302
Parts
02094B
84 33
43
91
1
28 25
34
56
47
39
24
64
46
84
27
58
8
86
32
30
37 18
37 59
97
55
26
99
98 13
52
55
40
27
32
42
30 31 57
36
54
54
34 (REF)
1See Detail A above.
2See Detail B at left.
4Part of item 36.
5Part of item 18.
3Part of item 1.
1
23
4
5
Detail B
Detail A 92
37
69
68
70
66
02095B
02095A