Graco Dyna-Star 236753 Datasheet

INSTRUCTIONS–P ARTS LIST 308–390
Rev. A
Dyna–Star
HYDRAULIC RECIPROCATOR & PUMP
1500 psi (105 bar) MAXIMUM HYDRAULIC INPUT PRESSURE
375 psi (26 bar  MAXIMUM FLUID OUTLET PRESSURE
1/4:1 RATIO UNIVERSALPUMP & RECIPROCATOR
Model 236–753, Series A, Stubby Length
RECIPROCATOR ONLY
Model 236–751, Series A
The pump is designed to dispense lube products
only. Any other fluids can cause unsafe operating
conditions and result in component rupture, fire or
explosion which could cause serious injury, includ-
ing
fluid injection.
WARNING
Patent No. 4,383,475
Foreign Patents Pending
Patent 1984 Canada
Brevete 1984
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terms 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reciprocator Repair 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 17. . . . . . . . . . . . . . . . . . . . .
Parts List & Drawing
Universal 1/4:1 Ratio Displacement Pump 19. . . . . .
Reciprocator 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawing and Mounting Hole Layout 23. .
Warranty 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Numbers 24. . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1994, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
Model 236–753 shown


2308-390
WARNINGS
High Pressure Spray Can Cause Serious Injury . For Professional Use Only.
Observe All W arnings. Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
The hydraulic reciprocator and pump can generate high
fluid pressure. Spray from leaks or ruptured components
can inject fluid through your skin and into your body and
cause extremely serious injury , including the need for
amputation.
Also, fluid injected or splashed into the eyes
or on the skin can cause severe damage.
Never point the dispense valve at anyone or at any part of
the body . Never put hand or fingers over the nozzle.
Always follow the Pressure Relief Procedure, right, be -
fore cleaning or removing the dispense valve nozzle or
servicing
any system equipment.
Never try to stop or deflect leaks with your hand or body .
Check operation of all equipment safety devices before
each
use.
Medical Alert––Airless Spray W ounds
If any fluid appears to penetrate your skin, get EMER-
GENCY
MEDICAL CARE A T ONCE. DO NOT TREA T
AS A SIMPLE CUT . Tell the doctor exactly what fluid
was injected.
Note to Physician: Injection in the skin is a traumatic in
jury. It is important to treat the injury surgically as
soon
as possible. Do not delay treatment to research
toxicity. T oxicity is a concern with some exotic coatings
injected directly into the blood stream. Consultation
with a plastic surgeon or reconstructive hand surgeon
may
be advisable.
Pressure Relief Procedure
To reduce the risk of serious injury , including fluid
injection, injury from moving parts, and splashing
in the eyes or on the skin, always follow this proce -
dure whenever you shut of f the pump, when
checking or servicing any part of the dispensing
system,
when installing, cleaning or changing dis -
pense
valve nozzles, and whenever you stop dis -
pensing.
1. Close the supply line shutof f valve, and then
the
return line shutof f valve.
2. Open the dispensing valve to relieve pres-
sure.
3. Place a container under the drain valve to
catch any drainage. Open the pump outlet
drain
valve.
4. Leave the drain valve open until you are ready
to dispense again.
If you suspect that the dispense valve 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 gradually , then loosen com-
pletely.
Clear the obstruction.
Emergency Stop Procedure
Close the supply line shutof f valve marked STOP.
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the dispensing equipment or accessories,
such as overpressurizing, modifying parts, using incom -
patible chemicals and fluids, or using worn or damaged
parts,
can cause them to rupture and result in injection or
other serious injury , fire, explosion or property damage.
Never alter or modify any part of this equipment; doing so
could cause it to malfunction.
Check all spray equipment regularly and repair or replace
worn or damaged parts immediately .
Always
read and follow the fluid and solvent manufactur -
er’s recommendations regarding the use of protective
eyewear,
clothing and equipment, including respirators.
Fluid Compatibility
BE
SURE that all fluids and solvents used are chemically
compatible with the wetted parts shown in the T echnical
Data
section on page 23. Always read the fluid and solvent
manufacturer’s literature before using them in your sys -
tem.
System Pressure
The reciprocator Maximum Hydraulic Input Pressure is
1500
psi (105 bar).
The displacement pump Maximum Fluid Outlet Pressure
is 375 psi (26 bar) .
The maximum working pressure of the pump is directly
proportional
to the pressure at which the reciprocator is op -
erated.
Be sure that any components or accessories added to
the
reciprocator power supply side or the pump fluid out -
let
side are rated to withstand this pressure.

3
308-390
HOSE SAFETY
High pressure fluid in the hydraulic hoses and pump fluid
outlet hoses can be very dangerous. If a hose develops a
leak, split or rupture due to any kind of wear , damage or
misuse, the high pressure spray emitted from it can
cause a fluid injection injury or other serious injury or
property
damage.
Tighten all fluid connections securely before each use.
High
pressure fluid can dislodge a loose coupling or allow
high pressure spray to be emitted from the
coupling.
Never
use a damaged hose. Before each use, check en -
tire
hose for cuts, leaks, abrasion, bulging cover , or dam -
age or movement of the hose couplings. If any of these
conditions exist, replace the hose immediately . Do not
recouple
high pressure hose. Never use tape or any de -
vice to try to mend the hoses; it cannot contain the high
pressure fluid.
Handle and route hoses carefully . Do not pull on hoses
to move equipment. Do not use fluids or solvents which
are not compatible with the inner tube and cover of the
hose.
Do not expose Graco hose to temperatures above
180_ F (82_ C) or below –40 _ F (–40_ C).
FIRE OR EXPLOSION HAZARD
Static electricity is created by the high velocity flow of
fluid through the reciprocator , pump and hose. If the
pump
is not properly grounded, sparking may occur , and
the system may become hazardous. Sparks from any
source
can ignite fumes from solvents and the fluid being
dispensed, dust particles and other flammable sub-
stances, and can cause a fire or explosion and serious
injury and property damage. Do not smoke, and do not
plug in or unplug any power supply cords in the spray
area when there is any chance of igniting vapors still in
the air.
If you experience any static sparking or even a slight
shock
while using this equipment, ST OP SPRA YING IM -
MEDIATELY.
Do not use the system again until the prob -
lem
has been identified and corrected.
Grounding
To reduce the risk of static sparking, ground the pump.
Check
your local electrical code for detailed grounding in -
structions
for your area and type of equipment.
1. Pump: use ground wire and clamp as shown to the
right.
2.
Hydraulic Hoses and Fluid Outlet Hoses: use only
electrically
conductive hoses.
3. Hydraulic Power Supply and Air Compressor: follow
manufacturer’s recommendations.
4. Any pails used when flushing. Use only metal,
grounded pails when flushing. Make firm metal–to–
metal contact between the a metal part of the dis-
pense valve and the pail. Use the lowest possible
pressure.
To ground the pump, loosen the grounding lug
locknut
(W) and washer (X). Insert one end of a 12
ga (1.5 mm @ ) minimum ground wire (Y) into the slot
in lug (Z) and tighten the locknut securely . Connect
the other end of the wire to a true earth ground. Re -
fer
to page 22 to order a ground wire and clamp.
ZX W
Y
03517
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers or
other body parts. Keep clear of moving parts when
starting or operating the pump. Follow the Pressure
Relief Procedure on page 2 before checking or serv -
icing the pump to prevent it from starting accidentally .
IMPORTANT
Terms
Be sure you read and understand each of these terms
before
reading the rest of the manual.
WARNING: Alerts user to avoid or correct conditions
which
could cause injury .
CAUTION: Alerts user to avoid or correct conditions
which could cause damage to or destruction of
equipment.
NOTE:
Gives additional information or helpful hints.
Safety Standards
United States Government safety standards have been
adopted under the Occupational Safety and Health Act.
These standards––particularly the General Standards,
Part
1910––should be consulted.

4308-390
Installation
KEY
AHydraulic
Fluid Control, 236–864
(See Manual 308–395)
B Porous Plug (W eep tube optional)
C Fluid Dispenser Outlet
D Drain V alve (Required)
F Hydraulic Return Line
G Hydraulic Outlet, 3/4 npt
H Return Line Shutof f V alve
J Hydraulic Inlet, 3/8 npt
K Hydraulic Supply Line Shutof f
Valve
L Pressure Gauge
M Pressure Reducing V alve
N Flow Control V alve
P Hydraulic Supply Line (Use only
GRACO hydraulic power supply)
Q Material Supply
R Ground Wire (Required)
SW all Mounting Bracket 236–778
(See Manual 308–394)
Typical Installation – Suction Feed System
Fig. 1
03516
R
F
P
A
H
K
M
N
B
J
Q
D
C
L
G
S
The installation shown above is only a guide. For assis -
tance in designing a system to suit your needs, contact
your
Graco representative.
Mount the pump to suit the type of installation planned.
See
page 22 for Accessories.
Maximum W orking Pressure of Accessories
To reduce the risk of serious bodily 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 (105 bar)
maximum working pressure and those to the pump
fluid outlet side must have at least a 375 psi (26 bar)
maximum working pressure.
WARNING
Pump Accessories
Suction Tube Kit A suction tube kit is available for si-
phoning
from 55 gallon containers.
Intake T ube (not shown) T o install, apply tape to
the female threads at the top of the tube. Screw the tube
tightly onto the intake housing of the stubby pump.
Low–level Cutoff Valve To install, screw the low–level
cutoff
valve into the bottom of the pump intake tube or the
suction tube. This valve closes the pump intake when the
fluid level is low, causing the pump to stall to avoid run-
ning
dry .
WARNING
Pump Outlet Drain V alve
A
pump outlet drain valve (D) is required in your sys -
tem. This valve helps relieve pressure in the dis-
placement
pump and hose when shutting down the
system and in case of a clogged outlet hose. Install
the valve close to the pump outlet.
Pump Outlet Drain V alve Install a drain valve (D) close
to the pump fluid outlet to assist in relieving fluid pressure
in the pump when the pump is shut of f.
Ground Wire A ground wire is required. See Acesso-
ries,
page 22.
PTFE

5
308-390
Installation
NOTE: Refer to the T ypical Installation to locate the parts
mentioned below .
Keep The Hydraulic System Clean
The hydraulic supply system must be kept clean at
all times to reduce the risk of damaging the recipro -
cator
hydraulic power supply . Blow out all hydraulic
lines with air , flush thoroughly with solvent, and then
blow out with air again before connecting the lines to
the reciprocator .
Always plug the hydraulic inlets, outlets and lines
when
disconnecting them for any reason to avoid in -
troducing dirt and other contaminants into the
system.
Carefully follow the manufacturer ’s recommenda-
tions on reservoir and filter cleaning, and periodic
changes
of hydraulic fluid.
CAUTION
Hydraulic Power Supply
WARNING
To reduce the risk of overpressurizing the hydraulic
reciprocator, which could cause a rupture and
serious bodily injury , including fluid injection, the
hydraulic
power supply must have a means to limit
the incoming fluid pressure developed in the system
to a maximum of 1500 psi (105 bar) .
Hydraulic Components
WARNING
Always turn off the hydraulic supply side valve (K,
Fig
1) first to avoid possible serious injury or compo -
nent
damage.
Hydraulic Fluid Control The hydraulic fluid control pro -
vides pressure regulation, flow regulation, and pump
isolation.
See Fig 1 for typical installation.
Pressure Regulation:
The hydraulic fluid control reduces the hydraulic oil
pressure to the operating pressure required for the
application.
Flow
Regulation:
The hydraulic fluid control limits the maximum
amount
of oil flow to the motor to keep the hydraulic
motor within the recommended cycle rate limit. This
prevents pump runaway . The limit on the Dyna-
Star
is 60 cpm.
Pump Isolation:
The hydraulic fluid control has ball valves on the sup -
ply
and return sides of the manifold. The ball valves
isolate the hydraulic fluid control and pump for serv -
icing
without stopping the hydraulic power supply .

6308-390
Operation
Before you start the pump
CAUTION
Recommended Hydraulic Oil
Use Graco-approved Hydraulic Oil or a premium,
ISO grade 46 petroleum-based hydraulic oil con -
taining rust and oxidation inhibitors and anti–wear
agents.See ACCESSORIES on page 22.
Before using any other type of oil in this motor ,
contact Graco Product Service, 1–800–543–0339.
Unauthorized use of lesser grade oil or substitutes
may void the warranty .
Hydraulic Oil W orking T emperature
The recommended hydraulic oil operating tempera -
ture is 80 – 1 15_ F (27 – 45_ C). The motor seals
will wear faster and leakage may occur if the pump
is operated at higher oil temperatures.
If the hydraulic oil temperature approaches 130 _ F
(54_
C), check the hydraulic fluid supply cooling
system, filters, etc. and clean or repair as needed.
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 using it for the first time to re -
move
the light oil which 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 TECHNI-
CAL DA TA, page 23. Flush until clean solvent
comes
from the outlet hose.
WARNING
How to relieve pressure
T o reduce the risk of serious bodily injury whenever
you shut of f the pump, check, service, clean or re -
pair any part of the system, always follow the Pres -
sure Relief Procedure on page 2.
Be sure you AL WA YS shut of f the hydraulic supply
line shutof f valve (K) first, and then the return line
shutof f valve. This is to prevent overpressurizing
the motor or its seals. When starting up the hydrau -
lic system, open the return line shutof f valve first.
To start the pump
WARNING
Maximum W orking Pressures
To reduce the risk of serious bodily injury including
fluid injection and splashing in the eyes or on the
skin, which may be caused if a component
ruptures:
Never exceed
1500 psi (105 bar) Maximum Hy-
draulic
Pressure to the reciprocator .
Never exceed
375 psi (26 bar) Maximum Outlet
Pressure
from the displacement pump.
Be sure all accessories added to the reciprocator
power supply side are capable of at least a 1500
psi
(105 bar) maximum working pressure and all of
those for the pump fluid outlet side have at least a
375 psi (26 bar) maximum working pressure .
The maximum working pressure of the displace-
ment
pump is directly  proportional to the pressure
at which the reciprocator is operated. Therefore, if
the fluid supplied to the reciprocator is 1000 psi (70
bar), the pump fluid outlet pressure will be 250 psi
(17.5 bar).
T
urn on the hydraulic power supply .
Open
the return line shutof f valve (H) first and slowly
open the hydraulic supply line shutoff valve (K).
Adjust the hydraulic inlet pressure from 500 to 1500
psi (35 to 105 bar) with the pressure reducing valve
control adjustment (M) on the hydraulic fluid control
(A). Increasing the inlet pressure increases the outlet
pressure. Decreasing the inlet pressure decreases
the
outlet pressure.
Always use the lowest pressure possible to obtain
the
desired results. This reduces pump wear .
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 of f the power sup -
ply
to the reciprocator immediately . Refill the supply
container and prime the pump to eliminate air .
NOTE: To prevent the pump from running dry , use a
low–level
cutof f valve.
If the reciprocator leaks at the fluid fittings
Tighten the fittings (16, 17, 25), which are self–sealing
and
have replaceable o–rings. If leaking persists, change
the o–rings.

7
308-390
Operation
Fig. 2
SELF–SEALING FIT -
TING
(16, 17, 25)
O–RING
RECIPROCATOR
03522
Shutdown & Care
Emergency Stop Procedure
Close the supply line shutof f valve marked STOP.
WARNING
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including
fluid injection, injury from moving parts, and
splashing
in the eyes or on the skin, always follow
this procedure whenever you shut of f the pump,
when
checking or servicing any part of the dispens -
ing system, when installing, cleaning or changing
dispensing
valve nozzles, and whenever you stop
dispensing.
1. Close the supply line shutof f valve, and then
the
return line shutof f valve.
2. Open the dispensing valve to relieve pressure.
3. Place a container under the drain valve to
catch any drainage. Open the pump outlet
drain
valve.
4. Leave the drain valve open until you are ready
to dispense again.
If you suspect that the nozzle or hose is completely
clogged, or that pressure has not been fully re-
lieved
after following the steps above, very slowly
loosen the hose end coupling to relieve pressure.
Clear
the obstruction.
Follow the preceeding Pressure Relief Procedure
Warning.
Always shut of f the supply line shutof f valve (K)
first , and then the return line shutof f valve (H). This is to
prevent overpressurizing the reciprocator or its seals.
When
starting the hydraulic system, open the return line
shutoff valve (H) first. See page 4.

8308-390
Notes

9
308-390
Troubleshooting Guide
To reduce the risk of serious bodily injury , including
fluid
injection, injury from moving parts, and splashing
in the eyes or on the skin, always follow this procedure
whenever you shut of f the pump, when checking or
servicing any part of the dispense system, when in-
stalling,
cleaning or changing dispense valve nozzles,
and whenever you stop dispensing.
1. Close the supply line shutof f valve, and then the
return
line shutof f valve.
2. Open the dispensing valve to relieve pressure.
3. Place a container under the drain valve to catch
any
drainage. Open the pump outlet drain valve.
4. Leave the drain valve open until you are ready to
pump again.
If you suspect that the nozzle or hose is completely
clogged,
or that pressure has not been fully relieved af -
ter
following the steps above, very slowly loosen the
hose end coupling to relieve pressure gradually . Clear
the obstruction.
WARNING
Pressure Relief Procedure
PROBLEM CAUSE SOLUTION
Pump won’t run. Closed dispense valve. Pump only runs with valve open.
Pressure too low .Increase supply pressure using the
pressure
adjusting valve.
Insuf ficient hydraulic fluid supply .Check hydraulic supply . Adjust to a
maximum
of 3 gpm (1 1 liter/min) flow .
Clogged fluid outlet line, intake
valve,
dispense valve, suction line.
Relieve pressure. Check; clear
obstructions.
Motor stalled. Press reciprocator reset button. Pump
should start immediately!
RESET
BUTTON
03518
Reciprocator damaged. Repair . See page 12 or 15.
Pump speeds up or runs erratically . Pump piston and/or intake
valve worn.
Relieve pressure. Check and repair .
See
page 17.
Empty supply container . Refill and reprime. Do not allow pump
to run dry . Monitor closely or use a low-
level cutof f valve.
Pump runs, but output low on up
and/or
down stroke.
Pump piston and/or intake valve
worn.
Relieve pressure. Check and repair .
See
page 17.
Pump runs but output low on both
strokes.
Insufficient hydraulic fluid supply . Check hydraulic supply .
Pressure too low .Increase supply pressure using the
pressure
adjustment on the control.
Clogged fluid outlet line, intake
valve,
dispense valve, suction line.
Relieve pressure. Check; clear
obstructions.
Excessive weepage from porous
plug
(B).
W orn throat seals.. Repair . See page 10.
Hydraulic oil leaks from fittings in the
upper or lower reciprocator blocks
(53, 47).
Fittings (16,17,25) are loose, or their
o–rings are worn or damaged.
Tighten the self-sealing fittings. If leak -
ing
persists, change the o–rings.

10 308-390
Service
Replacing Base Packing in Reciprocator. See
Fig
3.
NOTE: Replace these seals if fluid leaks excessively
through
the porous plug (107), see Fig 4. This procedure
can be done without disassembling the entire recipro-
cator.
1. Follow
the Pressure Relief Procedure W arning,
on page 9.
2. Disconnect the reciprocator from the pump. See
the procedure to the right.
3. Remove the four capscrews (24) and washers (12)
from the bottom of the retainer housing (56). T ap
the retainer housing to loosen it and pull it of f the
bottom cap (47).
4. Remove the seal (22) and sleeve bearing (34)
from the top of the retainer housing (56).
NOTE: Item 22 is included in the Repair Kit, 236–861.
5. Lubricate the sleeve bearing (34) and install the
seal and sleeve bearing in the retainer housing
(56) in the order shown in Fig 3 .
6.
Reassemble. T orque the capscrews (24) to 28–32
ft–lb (43–43 N.m). Install the displacement pump.
Follow Step 23, page 15.
Fig. 3
47
56
34
Lips face UP
03523
1TORQUE T
O 28–32 ft–lb (43–43 N.m)
1
2
222
12
24
Disconnecting Reciprocator and Displacement
Pump and Replacing Throat Seals.
See Fig 4.
Fig. 4
115
7, 6
28
118
119
115
03520
03515
Note: Piston rod 116
must install on conn-
ecting rod 45, first.
116
105
103
107
117
110
Fig 9–2
43
36,37
33
32
117
103
118
108
46 HIDDEN FROM VIEW
34

11
308-390
CAUTION
Keep The Hydraulic System Clean
It is essential to keep the hydraulic oil system clean
and free of contaminants to reduce the risk of dam -
aging the hydraulic reciprocator . Always install a
plug
in each tube fitting and on each hose end when -
ever fluid lines are disconnected to prevent
contamination.
1. Flush
the pump if possible and stop it with the pis -
ton rod in the lowest position.
2. Follow the Pressure Relief Procedure W arning,
on page 9.
3. Disconnect the outlet hose from the displacement
pump.
4.
Slowly loosen the hydraulic hoses to the supply
(26) and return (25) fittings to relieve any pressure,
and then remove the hoses. Install plugs on the
tube fittings and in the hose ends. Check the o–
ring (13) on the fitting and replace if worn or dam -
aged. See Fig 3 and the Parts Drawing.
Service
5. Using a strap wrench on the pump cylinder (1 18),
screw it out of the base (1 15) and remove it.
6. Place piston (1 17) in vise and loosen piston rod
(116). (1 18) from the bottom of the displacement
rod assembly (34). Screw the connecting rod out.
The pump is now free.
7. Remove bolts (105) and washers (103). (1 18) from
the bottom of the displacement rod assembly (34).
Screw the connecting rod out. The pump is now
free.
CAUTION
Be careful not to scratch the outside of the piston
rod.
Assembly after Replacing Throat Seals.
See Fig 4.
CAUTION
Be careful not to scratch the outside of the piston
rod.
8. Install
bolts (105) and washers (103). Torque to
20–25 ft-lb. 1 18) from the bottom of the displace -
ment rod assembly (34). Screw the connecting rod
out. The pump is now free.
9. Apply Loctite  242 to threads on piston (1 17).
Install ball (104). Screw piston into piston rod
(116). (1 18) from the bottom of the displacement
rod assembly (34). Screw the connecting rod out.
The pump is now free.
10. Place piston (1 17) in vise and tighten piston rod
(116). T orque to 155–175 ft-lb. (1 18) from the bot -
tom of the displacement rod assembly (34). Screw
the connecting rod out. The pump is now free.
11. Apply fresh grease and install a new o-ring (1 12)
on pump cylinder (1 18).
12.
Using a strap wrench on the pump cylinder (1 18),
screw it tightly into the base (1 15).

12 308-390
Reciprocator Repair
NOTE 1: Clean and inspect all parts for wear or dam-
age. Replace parts as needed. For the best
results, always replace all the o–rings and
seals when you disassemble the pump. Re-
pair
kit 236–861 is available. Parts included in
the kit are marked with an asterisk on the parts
lists.
NOTE 2: Assembly tool 181–619 is required for reas-
sembling the reciprocator. See Accessories
to order.
NOTE 3: For Step 10 and 1 1, Loctite  242 thread
sealant and
Loctite  Primer T OR Perma–
Loc
 11 5 thread sealant and Perma–Bond 
Surface Conditioner I are required. Be sure
their
shelf life is within the manufacturer ’ s rec -
ommendations.
1. Loosen
both nuts on the inlet tube (57). Use a
wrench to rotate the tube fittings (16, 17) to the
side, and then remove the tube (57). Install plugs
in the fittings to prevent contamination. See the
Parts Drawing.
2. Remove the capscrew (14), nuts (7) and lock
washers (6) on top of the reciprocator . See Fig 5.
Fig. 5
6, 7
47
14, 33, 27
03517
56
24
12
105
103
3.
Remove the four capscrews (24) and the retainer
housing (56). T ap the retainer housing with a plas -
tic mallet to loosen it and pull it of f the bottom cap
(47). See Fig 5. If needed, replace the throat seals
as described on page 10.
See Fig 8 for Steps 4 to 14, except where noted.
4. T ap on the bottom of displacement rod (54) with a
plastic mallet to loosen the motor cylinder (39).
5. Grasp the valve spool (31) and pull it of f the cylin -
der and tie rods (49). Pull the cylinder and piston
of f the bottom cap (47). It is not necessary to re -
move the tie rods from the cap.
6. Lay the assembly on its side. Place a clean rag
over the valve mechanism to prevent losing the
detent balls. Slide the guide clamp (30) down of f
the valve sleeve (32) while holding the balls (5)
and spring (20) in place.
7. Slide the cylinder (39) of f the displacement rod
(54). Hold the hex end of the displacement rod in a
vise and use a spanner wrench in the pin holes of
the piston (35) to screw it of f the rod.
CAUTION
Be careful not to scratch the outside of the displace -
ment rod.
8. V
isually inspect the spring (36). If there is wear or
damage, proceed with this step. Remove the nut
(19), spring (36) and retainers (55) from the trip
rod (40). Reassemble with a retainer (55) on each
end of the new spring (36). Adjust the nut to obtain
the dimension shown in Fig 6.
Fig. 6
55
36
19
55
1.580”
+/–
.015”
03524
40

13
308-390
Reciprocator Repair
Fig. 7
40
49
15
7,6
53
30
32
47
35
55
36
19
21
13
29
5,20
43
11
46
39
54
SEE FIG 7
55
13
37
38,18
14,33,27
52
45
03519
1
2
TORQUE T O 30–40 ft–lb (41–54 N.m)
APPLY THREAD ADHESIVE AND TORQUE PER STEP 10
1
2
48
31
9. Inspect the guide clamp (30) for wear or damage.
If replacement is necessary , remove the screw
(15) from the rod (40). Replace damaged parts
and the trip rod guides (29). Thoroughly clean any
adhesive residue from the screw (15) and the in -
ternal threads of the rod (40).
NOTE 1: Use a surface cleaner such as chlorinated sol -
vent on the threads and blow with com-
pressed air. A #10–24 UNC–2B tap can be
used to remove adhesive from the internal
threads
of the rod.
NOTE 2: Thread sealant and primer are required for
Step 10 and 11. See NOTE 3 on page 12 for
specifications.
10. Apply
three drops of fresh thread sealant to the
first two or three internal threads of the rod (40).
Apply primer to the external thread of the screw
(15). Let dry for three or four minutes. Assemble,
torquing the screw to 30–34 in–lb (3.4–3.8 N.m).
Remove excess sealant. Allow 24 hours to cure
before operating the reciprocator .
11.
Normally the valve sleeve (32) and valve stop (44)
do not have to be replaced. However , if either part
must be replaced, first soak the parts in hot water
to loosen the sealant. Clean all sealant from the
threads of any part you are reusing and apply
three drops of thread sealant to the first two or
three internal threads of the valve stop (44). Apply
primer to the external thread of the valve sleeve
(32). Let dry for three or four minutes. Assemble.
Remove excess sealant. Allow 24 hours to cure
before operating the reciprocator .
12.
Use a spanner wrench to screw the piston (35)
onto the displacement rod (54). T orque to 30–40
ft–lb (41–54 N.m).
13. Install the o–ring (18*) in the deep lower groove of
the piston (35) and install the seal (38*) over the
o–ring. Install the piston bearing (37*) around the
upper groove of the piston. Holding the piston
bearing in place to avoid damage, slide the cylin -
der over the piston and press it down.
CAUTION
When inserting the piston into the cylinder , carefully
guide the piston seal (38*) and bearing (37*) to pre -
vent
damaging these parts.
procedure continued on next page

14 308-390
Reciprocator Repair
Fig. 8
53
UPPER DETENT HOLES
ASSEMBLY B
T OOL 181–619
44
20
5
43
32
40
ASSEMBL Y A
03525
30
SLIDE CUR VED ENDS
INTO GROOVE OF
VAL
VE SLEEVE (32)
14. See Fig 8. Lay Assembly A and Assembly B on
the workbench.
15. Slide Assembly B into the the center of the tool.
Align the upper detent holes of the guide clamp
(30) with the center line of the tool. See Fig 8.
16. Insert the spring (20) and one ball (5) into the
valve stop (44) of Assembly A. T ilt the valve stop
and start guiding it into the tool, making sure the
ball is sliding into the rounded slot in the tool.
Place the other ball at the other end of the spring
and push it in with your thumb while rotating the
valve stop (44) until the spring is horizontal and the
balls are in place. Continue holding this assembly
together . See Fig 8.
17. Place your thumbs on the valve stop (44), grasp
the bottom of the tool with your other fingers and
press the assemblies together. Make sure the balls
(5) snap into the upper set of holes in the guide
clamp (30), and the curved ends of the guide
clamp have engaged the valve sleeve (32) groove.
See Fig 8. Slide the tool back over the rod (40) to
remove it.
procedure continued on next page

15
308-390
Reciprocator Repair
Refer to Fig 10 for Steps 18–24.
18. If the tie rods (49) were removed, reinstall them
with the short threaded end up. The other end
should be screwed about 9/16” into the bottom cyl -
inder cap (47).
NOTE 3: When reinstalling the cylinder (39) (Step 20),
be
sure the “P” port in the cylinder cap (53) and
the port in the bottom cylinder cap (47) are in
line with each other . Be sure the o–rings (13)
are in place in both cylinder caps.
19. Slide the cylinder (39) with the piston/displacement
rod already installed in it, into the groove in the
bottom cylinder cap (47). Position the spool valve
(31) over the cylinder and press down firmly .
20.
Install the capscrew (14), o–ring (33) and washer
(27). Install the lockwashers (6), nuts (7). T orque
the nuts to 28–32 ft–lb (36–43 N.m).
CAUTION
Never install the fluid tube (57) before torquing the
tie rods. Doing so could cause misalignment and
damage
the reciprocator when it is operated.
21. Reinstall the fluid tube (57) and fittings (17,16).
T orque the fittings to 25–35 ft–lb (34–48 N.m). See
the Parts Drawing on page 20.
22. Pull the displacement rod (54) in and out to be
sure it moves easily with only a little resistance
from the rod seal.
23. T o reconnect the reciprocator and pump, screw the
connecting rod (45) into the piston rod (1 16) and
torque to 75–85 ft-lb. Push the connected assem -
bly down through the base (1 15). Clean piston
(1 17) threads and apply Loctite  242. Install ball
(104). Screw piston (1 17) into piston rod (1 16).
Place assembly in a vise and torque to 155–175
ft-lb. Make sure the o–ring (1 12*) in the outside
groove of the pump cylinder (1 18) is in good condi -
tion. Push the cylinder up into the adapter and en -
gage the threads. Screw in the pump, using a
strap wrench for the final tightening.
24. Connect the hydraulic supply hose to fitting (26)
and return hose to fitting (25)
WARNING
To reduce the risk of static sparking be sure to re-
connect
the ground wire before operating the pump.
45
Fig. 9
7,6
53
47
13
39
22
14,33.27
56
49
TORQUE T O
28–32 FT–LB
(36–43 N.M)
03519
118
110
115
03520
116
1
1
54
NOTE: During assembly
screw (45) in o
(116) firs .
117

16 308-390
Notes

17
308-390
Displacement Pump Repair
Intake V alve. See Fig 10.
1. If possible, flush the pump. Follow the Pressure
Relief Procedure W arning on page 9 .
2.
Unscrew the valve body (1 19). Remove the o–ring
(108), ball (106) and retainer (120).
3.
Inspect the parts for wear or damage. If the ball is
nicked, replace it. Reassemble, using grease on
the male threads.
Displacement Pump. See Fig 10.
NOTE 4: Clean and inspect all parts for wear or damage
as you disassemble them. Replace parts as
needed. For the best results, always replace
all
the o–rings and packings when you disas -
semble the pump. The parts list on page 19
gives the recommended parts to keep on
hand.
1. If
possible, flush the pump. Follow the Pressure
Relief Procedure W arning on page 9 .
2.
Follow Disconnecting the Reciprocator and
Displacement Pump on page 9. Remove the in -
take valve.
3. Carefully inspect the smooth, inner surface of the
cylinder (1 18) for scoring or irregular surfaces.
Such damage causes premature seal wear and
leaking, so replace the part if needed.
4. Grease the new piston seal and install with the lips
facing up as shown in Fig 10.
5. Reconnect reciprocator and displacement pump
per steps 1 through 6 of Assembly after Re-
placing Throat Seals
on page 1 1.
Fig.10
115
116
104
112
117
120
106
108
119
03520
110
1Lips face down
1
2Lips face up
2
108
118

18 308-390
Notes

19
308-390
Model 236–753 1/4:1 Ratio Pump – Parts
REF
NO. PART
NO. DESCRIPTION QTY
REF
NO. P ART NO. DESCRIPTION QTY
101 236–751 RECIPROCAT
OR, hydr , Dyna-Star 1
see parts on page 20
103 100–133 W ASHER, lock; 3/8 1
104 101–178*
BALL, metallic 1
105 102–637 SCREW
, cap hex hd; 3/8–16 x 1
1–1/2
106 108–001*
BALL, metallic, sst 1
107 110–064
PLUG, pipe, vented; 1/8–27 npt(f) 1
108 110–828* P
ACKING, o-ring 1
110 112–558*
SEAL, block vee 1
111 112–565*
SEAL, block vee 1
112 166–071* P
ACKING, o-ring 1
115 189–705
BASE, motor , hydraulic 1
116 189–706
ROD, piston 1
117 189–707 SEAT
, valve 1
118 189–708
CYLINDER, pump 1
119 189–709 VAL
VE, housing 1
120 189–710 RET
AINER, ball 1
121 189–711 WASHER,
piston 1
*Included in Repair Kit 236–681. See page 22 for Accesso -
ries.
121
120
119
118
117
111
112
110
103
105
104
108
116
106
101
03528
03529
03527
115
107
Note: Item 116 of p mp
m st be connected to
item 45 of reciprocator
first d ring assembly.

20 308-390
Hydraulic Reciprocator – Parts
MODEL 236–751, Series A
Hydraulic Reciprocator
Includes items 5 to 57 NOTE:
See pages 10 to 15 for
important assembly
procedures and torque
values.
7
6
45
10 8
12
24
56
22
51
53
23
52
44
21
39
40
49
35
18
37
55
36
19
54
20
5
9
31
32
25
26
17
27
13
13
11
38
15
46
48
43
30
29
57
16
14
47
33
03526
50
28
55
11
34