Graco Dyna-Star 224912 User manual

Instructions
Dyna-Star™Hydraulic
Reciprocator and Pump 308156S
EN
For lubricating fluids only. For professional use only.
5:1 Ratio Universal Pump and Reciprocator
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
7500 psi (51 MPa, 517 bar) Maximum Fluid Outlet Pressure
Model 224912, Series C
35 lb. pail size
Model 224751, Series C
120 lb. drum size
Model 224752, Series C
400 lb. drum size
Model 239883, Series A
reciprocator only
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.

2308156S
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump Accessories . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . 7
Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 9
Before Starting the Pump . . . . . . . . . . . . . . . . . . 9
To Start the Pump . . . . . . . . . . . . . . . . . . . . . . . . 9
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
If the Pump Leaks at the Fluid Fittings . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacing the Throat Seals . . . . . . . . . . . . . . . . 12
Disconnecting the Reciprocator and Displacement
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reciprocator Repair . . . . . . . . . . . . . . . . . . . . . 13
Displacement Pump Repair . . . . . . . . . . . . . . . 18
Parts - Displacement Pumps . . . . . . . . . . . . . . . . 20
Parts - Reciprocator . . . . . . . . . . . . . . . . . . . . . 21
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dimensions and Mounting Hole Layout . . . . . . . 25
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . 26

Warnings
308156S 3
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 or on warning labels, 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
When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be
aware that flammable fumes can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as cigarettes and portable electric lamps.
• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Ground all equipment in the work area.
• Use only grounded hoses.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings
4308156S
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 com-
ponent. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from 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 manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• 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.
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
swallowed.
• Read MSDSs 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.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
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,
follow the Pressure Relief Procedure and disconnect all power sources.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective 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
WARNING

Installation
308156S 5
Installation
Grounding
Pump: Use ground wire and clamp as shown in FIG. 1.
Hydraulic hose and fluid outlet hoses: use only elec-
trically conductive hoses.
Hydraulic power supply: Follow manufacturer’s recom-
mendations.
Any pails used when flushing: Use only metal,
grounded pails when flushing. Make firm metal-to-metal
contact between the metal part of the dispense valve
and the pail. Use the lowest possible pressure.
To ground the pump: Remove the ground screw (Z)
and insert through the eye of the ring terminal at end of
ground wire (Y). Fasten the ground screw back onto the
pump and tighten securely. Connect the other end of the
ground wire to a true earth ground. (FIG. 1)
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
FIG. 1
Y
Z

Installation
6308156S
Key:
A Follower plate
B Weep tube
C Fluid outlet line (to gun)
D Drain valve (required)
E Ground wire
F Hydraulic return line, minimum 3/4” I.D. (required)
G Hydraulic outlet, 1/2 npt
H Return line shut-off valve, minimum 3/4” (required)
J Hydraulic inlet, 1/2 npt
K Tee, 3/4 npt
L *Supply line shut-off valve
M *Pressure gauge
N *Pressure reducing valve (required in systems over 1500
psi [10.2 MPa, 102 bar])
P Accumulator
R *Flow control valve (required in systems over 3 gpm [11
lpm])
S Hydraulic supply line
T Check valve
U Variable volume pressure compensated pump
V Hydraulic power supply
W Drain line, accumulator
* Included in Hydraulic Fluid Control Kit, 236864, which can be ordered separately.
Although the installation shown in FIG. 2 is only a guide for selecting and installing system components and accesso-
ries, some equipment is required, as noted in the key. For assistance in designing a system to suit your needs, con-
tact your Graco distributor.
Mount the pump to suit the type of installation planned.
FIG. 2: Typical Installation
A
B
C
D
E
FGHJK
L
M
N
P
R
S
TU
V
W

Installation
308156S 7
Pump Accessories
• Follower plate (A) ensures a good prime. Place the
plate on the grease and rotate while pressing firmly
to level the material.
• Pump outlet drain valve (D) helps relieve fluid pres-
sure in the pump when the pump is shut off. Install
the valve close to the pump fluid outlet. Order Part
No. 111229, valve.
Hydraulic System
The hydraulic supply system must be kept clean at all
times to reduce the risk of damaging the reciprocator
hydraulic power supply. Blow out all hydraulic lines with
air, flush thoroughly with solvent, and blow out with air
again before you connect the lines to the reciprocator.
Always plug the hydraulic inlets, outlets, and lines when
you disconnect them for any reason to avoid introducing
dirt and other contaminants into the system.
Carefully follow the manufacturer’s recommendations on
cleaning the reservoir and filter and periodically chang-
ing the hydraulic fluid.
Hydraulic Power Supply
The hydraulic power supply system (V) must have a
pressure reducing valve and a pressure-compensated
flow control. A flow control valve (R) is required to limit
the incoming flow to the reciprocator to a maximum of 3
gpm (11 lpm).
NOTE: A supply line shut-off valve (L), pressure gauge
(M), pressure reducing valve (N), and a flow control
valve (R), are including in the Hydraulic Fluid Control Kit,
236864, which can be ordered separately.
Maximum Working Pressure of Accessories
To reduce the risk of serious injury including fluid
injection and splashing in the eyes or on the skin,
which may be caused if a component ruptures, all
accessories added to the reciprocator power supply
side must have at least a 1500 psi (10 MPa, 102 bar)
maximum working pressure.
All accessories added to the pump fluid outlet side
must have at least a 7500 psi (51 MPa, 517 bar)
maximum working pressure.
NOTICE
Pump Outlet Drain Valve
A pump outlet drain valve (D) is required in your
system. This valve helps relieve pressure in the
displacement pump and hose when the system is
shut down and if the outlet hose gets clogged. Install
the valve close to the pump outlet.
Limit Fluid Flow to Reciprocator
To reduce the risk of over-pressurizing the hydraulic
reciprocator, which could cause a rupture and
serious injury, including fluid injection, the hydraulic
system must have a means to limit the incoming fluid
flow to the reciprocator to a maximum of 3 gpm (11
lpm) and 1500 psi (10.2 MPa, 102 bar).

Installation
8308156S
Hydraulic Lines
Refer to FIG. 2 for the parts mentioned in the following
instructions.
• Shut off valves (H and L): Installed in the hydraulic
supply and return lines.
• Drain Line: Remove the plug (59) from the pump
adapter, and install a 1/8 diameter weep tube (B),
ending in a waste container. Monitor the weepage of
hydraulic fluid. If it seems excessive or increases
suddenly, the reciprocator/pump seals may need to
be changed. (FIG. 3)
• Hose: Use a minimum 1/2” supply line (R) and mini-
mum 3/4” return line (F) on the reciprocator. Contact
your Graco representative for details of line sizing.
• Pressure reducing valve (N): Circulates excess
hydraulic fluid pressure back to the hydraulic power
supply. Install this valve (N) in the hydraulic supply
line with a drain hose teed into the hydraulic return
line (F). Limit supply pressure to a maximum of
1500 psi (10.2 MPa, 102 bar).
• Accumulator (P): Reduces the hammering effect
caused by the motor when it reverses direction.
• Fluid-filled pressure gauge (M): Monitors hydraulic
pressure to the reciprocator during start up. Use the
gauge for initial adjustment of the reciprocator. It
can be removed after adjustment is made.
FIG. 3
59

Operation
308156S 9
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Shut off the hydraulic power supply.
2. Close the supply line shut-off valve (L, FIG. 2).
3. Open the dispensing valve to relieve pressure.
4. Open the pump outlet drain valve and have a con-
tainer ready to catch the drainage.
5. Close the return line shut-off valve (H).
NOTE: Leave the drain valve open until you ar ready to
dispense again.
If you suspect that the nozzle or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, very slowly loosen the
hose end coupling to relieve pressure, then clear the
obstruction.
Before Starting the Pump
1. Check the hydraulic fluid level in the hydraulic power
supply before each use, and add fluid as necessary
to fill the lines.
2. Flush the pump before you use it for the first time to
remove the light oil that was left in after factory test-
ing to protect the pump from corrosion. Be sure the
solvent used is compatible with the fluid to be
pumped and the pump wetted parts. See Technical
Data, page 24. Flush until clean solvent comes from
the outlet hose.
To Start the Pump
1. Turn on the hydraulic power supply.
2. Open the return line shut-off valve (H), and slowly
open the hydraulic supply shut-off valve (L).
3. Adjust the flow control valve (R) to limit the hydraulic
flow to no more than 3 gpm (11 lpm), which is
approximately 60 cycles per minutes.
NOTE: If Graco Part No. 236864 hydraulic fluid control
is used, no adjustment is necessary.
4. By adjusting the pressure reducing valve (N), adjust
the hydraulic inlet pressure from 50 to 1500 psi
(0.34 to 10.2 MPa, 3.4 to 102 bar). Increasing the
inlet pressure increases the outlet pressure.
Decreasing the inlet pressure decreases the outlet
pressure.
5. Always use the lowest pressure possible to obtain
the desired results. This reduces pump wear.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
NOTICE
Always use Graco approved hydraulic oil or equiva-
lent, Part No. 169236 (5 gallon) or 207428 (1 gallon).
Do not substitute lower grade oil.
NOTICE
Never allow a pump to run dry of the fluid being
pumped. A dry pump quickly speeds up and can
damage itself. If it speeds up, shut off the power sup-
ply to the reciprocator immediately. Refill the supply
container, and prime the pump to eliminate air.

Operation
10 308156S
Shutdown
Relieve the pressure whenever you shut down. See
Pressure Relieve Procedure on page 9.
If the Pump Leaks at the Fluid
Fittings
Tighten the fittings (1, 5, 58), which are self-sealing and
have replaceable o-rings. If leaking persists change the
o-rings.
10
FIG. 4
self-sealing
fitting (1,5,58)
o-ring
(1a,5a,58a)
reciprocator

Troubleshooting
308156S 11
Troubleshooting
1. Follow Pressure Relief Procedure, page 9, before
checking or repairing gun.
2. Check all possible problems and causes before dis-
assembling gun.
Problem Cause Solution
Pump won’t run
Closed dispense valve Pump only runs with valve open.
Pressure too low Increase supply pressure using a
pressure adjusting valve.
Insufficient hydraulic fluid supply Check hydraulic supply. Adjust to a
maximum of 3 gpm (11 lpm) flow.
Clogged fluid outlet line, intake
valve, dispense valve, suction line
Relieve pressure. Check; clear
obstruction.
Reciprocator damaged Repair. See page 12.
Pump speeds up or runs erratically
Pump piston and/or intake valve is
worn
Relieve pressure. Check and repair.
See page 12
Empty supply container.
Refill and reprime. Do not allow
pump to run dry. Monitor closely or
use a low-level cutoff valve.
Pump runs, but output low on up
and/or down stroke
Pump piston and/or intake valve
worn Relieve pressure. Check and repair.
Pump runs but output low on both
strokes
Insufficient hydraulic fluid supply Check hydraulic supply. Adjust to
maximum 3 gpm (11 lpm) flow.
Pressure too low Increase supply pressure using a
pressure adjusting valve.
Clogged fluid outlet line, intake
valve, dispense valve, suction line
Relive pressure. Check; clear
obstructions.
Excessive weepage from weep tube
(B) Worn throat packings Repair. See page 12.
Hydraulic oil leaks from fittings in
the upper or lower reciprocator
blocks (31, 32)
Fittings (1, 5, 58) are loose, or their
o-rings are worn or damaged
Tighten the self sealing fittings. If
leaking persists, change the o-rings.

Repair
12 308156S
Repair
Replacing the Throat Seals
Refer to FIG. 5 for the following instructions.
NOTE: Replace the seals if fluid leaks excessively
through the weep tube (B). This procedure can be done
without disassembling the entire reciprocator.
1. Relieve the pressure. See Pressure Relief Proce-
dure, page 9.
2. Disconnect the reciprocator from the pump. See
Disconnecting the Reciprocator and Displacement
Pump on page 13.
3. Remove the four capscrews (46) from the bottom of
the adapter (43). Tap the adapter to loosen it, and
pull it off the bottom cap (32).
4. Remove the seals (16, 44) and guide (19) from the
top of the adapter (43).
5. Lubricate the guide (19) and install the seals and
guide in the adapter (43) one at a time in the order
shown in FIG. 5.
6. Reassemble. Torque the capscrews (46) to 28 to 32
ft-lbs (38 to 43 N.m). Install the displacement pump.
Follow Step 24, page 18.
NOTICE
Keep the Hydraulic System Clean
It is essential to keep the hydraulic oil system clean
and free of contaminants to reduce the risk of damag-
ing the hydraulic reciprocator. Always install a plug in
each tube fitting and on each hoe end whenever fluid
lines are disconnected to prevent contamination.
FIG. 5
32
33
46
43
44*
1Torque to 28 to 32 ft-lb (38 to 43 N-m).
1
216*
16*
19
4
3
2
3
4
Lips face up.
Lips face down.
Lubricate.

Repair
308156S 13
Disconnecting the Reciprocator
and Displacement Pump
Refer to FIG. 6 for the following instructions.
NOTE: When displacement pump 224914 is purchased
separately, it comes with the priming piston (112) and
priming cylinder (111) un-assembled. Connect the dis-
placement pump to the hydraulic reciprocator before
assembling the priming piston and cylinder. Torque the
priming piston to 35 ft-lbs (47 N.m).
1. Flush the pump if possible and stop it with the dis-
placement rod in the lowest position.
2. Relieve the pressure, see Pressure Relief Proce-
dure, page 9.
3. Disconnect the outlet hose rom the displacement
pump.
4. Slowly loosen the hydraulic supply (58) and return
(5) fittings to relieve any pressure, and remove the
hoses. Install plugs on the tube fittings and in the
hose ends. Check the o-rings (5a, 58a) on the fit-
tings, and replace them if they are worn or dam-
aged. See FIG. 4 and the Parts Drawing.
5. Using a strap wrench on the displacement cylinder
(108), screw it out of the pump adapter (43), and
pull it off the pump.
6. Pull the connecting rod (35) down as far as it will go.
7. Remove the cotter pin (204) from the bottom of the
displacement rod assembly (34), and unscrew the
connecting rod until it is free.
NOTE: For the 35 lb. length pump, the priming cylinder
(111) and the priming piston (112) must be completely
removed before you can pull down the displacement cyl-
inder (108) far enough to remove the cotter pin (204).
8. Unscrew the piston coupling (103) to remove the
pump.
Reciprocator Repair
NOTE:
• Clean and inspect all parts for wear or damage.
Replace parts as needed. For the best results,
always replace all the o-rings and seals when you
disassemble the pump. Repair Kit 223426 is avail-
able.
• Assembly tool 189305 is required for reassembling
the reciprocator.
• Loctite®242 thread sealant and Loctite®Primer T or
Perma-Loc®115 thread sealant and Perma-Bond®
Surface Conditioner 1 are required. Be sure their
self life is within the manufacturer’s recommenda-
tions.
FIG. 6
43
36,37
33
32
46 (hidden from view)
35
202*
203*
101
103
204
3

Repair
14 308156S
NOTE: Use Loctite®609 on yoke (9) and rod (12) on
page 14, step 10 only. Use Loctite®242 or Perma-Loc®
115 on other threaded surfaces as required.
Before you begin, drain the oil out of the reciprocator as
follows: Place the reciprocator in a drain pan, push the
piston all the way up/in, then all the way down/out.
1. Place the adapter (43) in a vise. Remove the four
capscrews (46) and the base (33). Pull the bottom
cap (32) off the adapter. See FIG. 7. If needed,
replace the seals as described in Repair on page
12.
2. Remove the capscrew (3), nuts (36), and lockwash-
ers (37) on top of the reciprocator. (FIG. 7)
3. Loosen both nuts on the fluid tube (45). Use a
wrench to rotate the tube fittings (1, 58) to the side,
and remove the tube (45). Check the o-rings (1a,
58a) on the fittings, and replace them if they are
worn or damaged. Install plugs in the fittings to pre-
vent contamination. (FIG. 4)
4. Remove the capscrew (3), nuts (36) and lockwash-
ers (37) on top of the reciprocator. See FIG. 7.
NOTE: See FIG. 9 for steps 4 to 20, except where noted.
5. Tap on the bottom of the displacement rod (34) with
a plastic mallet to loosen the cylinder (25).
6. Grasp the spool valve assembly (31), and pull it off
the cylinder and tie rods (38). Pull the cylinder and
piston off the bottom cap (32). It is not necessary to
remove the tie rod from the bottom cap.
7. Lay the assembly on its side. Place a clean rag
around the yoke (9) to prevent losing the detent
balls. Slide the yoke sideways off the valve sleeve
(29) while holding the balls (7) and spring (6) in
place.
8. Slide the cylinder (25) off the displacement rod (34).
Hold the hex end of the displacement rod in a vise,
and use a spanner wrench in the pin holes of a pis-
ton (22) to screw it off the rod.
NOTE: Be careful not to scratch the outside of the dis-
placement rod or the inside of the cylinder.
9. Visually inspect the spring (21) if there is wear or
damage, proceed with this step. Remove the nut
(18), spring (21), and retainers (20) from the trip rod
(12). Reassemble with a retainer (20) on each end
of the new spring (21). You must thread the nut onto
the rod until it runs out of thread, so that it bottoms
out on the should of the rod. (FIG. 8)
NOTE: If you are re-using or reassembling any parts,
use a surface cleaner such as chlorinated solvent on the
threads, and blow with compressed air. A 1/4-28
UNF-2A tap can be used to remove adhesive from the
internal threads of the yoke (9).
Thread sealant and primer are required. See Reciproca-
tor Repair Notes on page 13 for specifications. Loctite®
609 is used only in STEP 10.
10. Apply fresh Loctite®609 thread sealant to the first
two or three internal threads of the yoke (9). Apply
primer to the external threads of the rod (12). Let
dry for three or four minutes. Assemble, torquing
screws to 54 to 56 in-lbs (6.1 to 6.3 N.m). Remove
excess sealant. Allow 24 hours to cure before oper-
ating the reciprocator.
FIG. 7
43
36,37
33
32
3,39,2
46
hidden from view
FIG. 8
20
21
20
18
12

Repair
308156S 15
11. Clean all sealant from the threads of any part you
are reusing, and apply Loctite®242 or Perma-Loc®
115 thread sealant to the first two or three internal
threads of the valve assembly (31). If you removed
the capscrew (51), apply thread sealant to the first
two or three internal threads of the valve stop (26).
Apply primer to the external threads of the valve
sleeve (29). Let it dry for three or four minutes,
assemble, and remove excess sealant. Allow 24
hours for the thread sealant to cure before you oper-
ate the reciprocator.
12. Remove the o-ring (13) from the bottom of the spool
valve assembly (31), and replace it with a new
o-ring.
13. Use a spanner wrench to screw the piston (22) onto
the displacement rod (34). Torque to 30 to 40 ft-lbs
(41 to 54 N.m).
NOTICE
When inserting the piston into the cylinder, carefully
guide the piston seal (23) and bearing (24) to prevent
damaging these parts.
FIG. 9
12
38
36,37
31
29
32
22
20
21
18
51
17
*13
6,7
9
17
25
34
See
Fig. 8
20
13*
*24
23*,49*
3,39,2
30
1
1
2
Torque to 42 to 45 in-lb (4.7 to 5.1 N-m)
2
Torque to 30 to 40 ft-lb (41 to 54 N-m)
26

Repair
16 308156S
14. Lay Assembly A and Assembly B on the work
bench. (FIG. 10)
15. Slide Assembly B into the center of the tool (D).
Align the upper detent holes (C) of the guide yoke
(9) with the center line of the tool (D). (FIG. 10)
16. Insert the spring (6) and one ball (7) into the vale
stop (26) of Assembly A. Tilt the valve stop, and
start guiding it into the tool (D), making sure the ball
is sliding into the rounded slot in the tool (D). Place
the other ball at the other end of the spring, and
push it in with your thumb while rotating the valve
stop (26) until the spring is horizontal and the balls
are in place. Continue holding this assembling
together. (FIG. 10)
17. Slide the valve stop assembly down onto the tool.
Make sure the balls (7) snap into the upper set of
holes (C) in the guide yoke (9), and the curved ends
of the guide clamp have engaged the valve sleeve
(29) groove. (FIG. 10) Slide the tool (D) back over
the rod (12) to remove it.
18. Place the adapter (43) in a vise, and install the seals
as described on page 12. Install the cylinder cap
(32). (FIG. 12)
19. If the tie rods (38) were removed, reinstall them with
the short threaded end up. The other end should be
screwed about 9/16” into the bottom cylinder cap
(32). (FIG. 12)
NOTE: When reinstalling the cylinder (25), be sure the
“P” port in the valve spool (31) and the port in the bot-
tom cylinder cap (32) are in line with each other. Be sure
the o-rings (13) are in place in the valve spool and cylin-
der cap.
20. Place the cylinder (25) on the cylinder cap (32).
Install the piston (22) and valve assembly (31).
21. Install the o-ring (49) in the deep lower groove of the
piston (22), and install the seal (23) over the o-ring.
Install the piston bearing (24) around the upper
groove of the piston. Holding the piston bearing in
place to avoid damage, slide the cylinder over the
piston and press it down. (FIG. 12)
22. Install the capscrew (3), o-ring (39), and washer (2).
Install the lockwashers (37) and nuts (36). Torque
the nuts to 28 to 32 ft-lbs (36 to 43 N.m).
FIG. 10
31
ASSEMBLY B
26
6
7
9
29
12
ASSEMBLY A
C
D
NOTICE
Never install the fluid tubes (45) before you torque the
tie rods. Doing so could cause misalignment and
damage the reciprocator when it is operated.

Repair
308156S 17
23. Reinstall the fluid tube (45) and fittings (1). Torque
the fittings to 25 to 35 ft-lbs (34 to 48 N.m) See
Parts Drawing, page 20.
24. Pull the displacement rod (34) in and out to be sure
it moves easily. (FIG. 12)
25. To reconnect the reciprocator and pump, install the
o-ring (17). Screw the connecting rod (35) into the
displacement rod (34). Install the cotter pin (204).
Install a new copper gasket (202). Make sure the
seal (203) in the bottom of the adapter (43) is in
good condition. Push the cylinder up into the
adapter and engage the threads. Screw in the pump
using a strap wrench for the final tightening. (FIG.
11)
26. Connect the hydraulic supply and return hoses to
the fittings (5, 60).
FIG. 11
To reduce the risk of static sparking be sure to
re-connect the ground wire before operating the
pump.
*202
204
118
103
203*
43
35
1
Torque to 150 to 160 ft-lb (205 to 220 N-m)
1
FIG. 12
36,37
31
32
*13
25
13*
3,39,2
43
38
35
1
1
Torque to 28 to 32 ft-lb (36 to 43 N-m)

Repair
18 308156S
Displacement Pump Repair
Disassembly
Refer to FIG. 13.
1. If possible, flush the pump. Relieve the pressure,
see Pressure Relief Procedure, page 9.
2. Follow Disconnecting the Reciprocator and Dis-
placement Pump procedure on page 13.
3. Place the pump in a vise. Unscrew the priming cylin-
der (111).
4. Push the priming piston (112) into the pump until the
hex of the piston coupling (103) is exposed.
5. Hold the piston coupling (103) and unscrew the pis-
ton rod (119).
6. Unscrew the packing housing (110) and remove all
parts.
7. Pull the piston (107) and the priming tube (108)
assembly out of the pump housing.
8. Unscrew the priming tube (108) and remove all
parts.
9. Unscrew the piston (107) and remove all parts.
10. Clean all parts thoroughly with a compatible solvent.
Inspect the parts for wear and replace as needed.
Scoring or irregular surfaces on the priming tube
(108) or inside the cylinder (118) cause premature
packing wear and leaking.
FIG. 13
Insert 1/4” dia. rod through hole to hold priming
tube (108) when removing or installing parts
connected to it.
1
116
102
115
104*
105*
106
102
115
101
103
107
117
116
108
119
111
112
109
114*
113*
118
110
2
1Only used on Models 223513 and 223514.
2

Repair
308156S 19
Reassembly
Refer to FIG. 14. for the following instructions.
NOTE:
• The balls (116) cannot be re-seated on the hard-
ened seats (102). The seats can be reversed and
used a second time however.
Lubricate all parts with a light, waterproof grease.
1. Insert the pin (101) into the piston coupling (103)
and insert the pin (117) into the pump piston (107).
2. Put the pump piston (107) in a vise and stack the
spacer (106), seal (105), packing (104), gasket
(115), seat (102), and ball (116) on it in the order
shown in FIG. 14. Thread the piston coupling (103)
onto the pump piston (107), and torque it to 60 ft-lbs
(80 N.m).
3. Turn the pump piston (107) over in the vise and
insert the ball (116), seat (102), and gasket (105).
4. Assemble the seal (113), packing (114), and bear-
ing (109) on the packing housing (110). Screw the
packing housing into the cylinder (118) and torque
to 60 ft-lbs (80 N.m).
5. Slide the assembly into the cylinder from the top.
Use your finger to guide the assembly through the
lower seals.
6. Models 223513, 223514 only: Screw the piston rod
(119) onto the priming tube (108). Torque to 35 ft-lbs
(47 N.m).
7. Place the gasket (202) in the base of the reciproca-
tor. Place the o-ring (203) into the groove of the
pump adapter (43). Screw the cylinder into the
pump adapter.
8. Firmly screw the priming piston (112) onto the pis-
ton rod (119). Torque to 35 ft-lbs (47 N.m).
9. Firmly screw the priming cylinder (111) onto the cyl-
inder (118).
10. Reconnect the ground wire to the reciprocator if it is
disconnected.
FIG. 14
1
116
102
115
104*
105*
106
102
115
101
103
107
117
116
108
119
111
112
109
114*
113*
118
110
4
1
2 3
2
1
2
3
4
Torque to 60 ft-lb (80 N-m).
Torque to 35 ft-lb (47 N-m).
Only used on Models 223513 and 223514.
Insert 1/4” dia. rod through hole to hold priming
tube (108) when removing or installing parts
connected to it.
1

Parts - Displacement Pumps
20 308156S
Parts - Displacement Pumps
Model 223513, Series A, 120 lb, Includes items 101 to 119
Model 223514, Series A, 400 lb, Includes items 101 to 119
Model 224914, Series A, 35 lb, Includes items 101 to 118
†Parts included in Kit 223427 (purchase separately).
Ref. Part Description Qty.
101 108992 PIN, spring 1
102 162559 SEAT, valve 2
103 183670 COUPLING, piston 1
104† 108990 PACKING, block 1
105† 108989 SEAL, back up 1
106 183669 SPACER, piston 1
107 183676 PISTON, pump 1
108 183677 TUBE, priming 1
109 183668 BEARING, priming 1
110 183675 HOUSING, packing 1
111 183673 CYLINDER, priming, model 223513 1
185999 CYLINDER, priming, model 223514 1
187312 CYLINDER, priming, model 224914 1
112 183672 PISTON, priming 1
113† 108988 SEAL, back up 1
114† 108987 PACKING, block 1
115 150451 GASKET, copper 2
116 100170 BALL 2
117 108991 PIN, spring 1
118 183678 CYLINDER, pump 1
119 186002 ROD, piston, model 223513 1
185998 ROD, piston, model 223514 1
101
118
112
111
109
*114
*113
110
116
102
115
108
116
102
115
105*
106
117
103
107
119
104*