Graco Dyna-Star 239882 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1991, Graco Inc. is registered to I.S. EN ISO 9001
Dyna–Start
HYDRAULIC RECIPROCATOR AND PUMP
FOR LUBRICATING FLUIDS ONLY
1:1 Ratio Universal Pump and Reciprocator
Model 239882, Series A, Reciprocator Only
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet Pressure
Model 224741, Series C, Stubby Length
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet Pressure
Model 224742, Series C, 55-Gallon Length
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet Pressure
Model 237653, Series B, Stainless Steel Stubby Length Pump
1000 psi (7 MPa, 69 bar) Maximum Hydraulic Input Pressure
1000 psi (7 MPa, 69 bar) Maximum Fluid Outlet Pressure
308155M
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
See page 26 for Maximum Working Pressures.
Model 224741 shown
Patent No. 4,383,475
Foreign Patents Pending
Patent 1984 Canada
Brevete 1984
06143C
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reciprocator Parts Drawing, Model 239882 18. . .
Reciprocator Parts List, Model 239882 19. . . . . . . .
Displacement Pump Repair,
Models 239882, 224741, and 224742 20. . . . . . . . .
Displacement Pump Parts Drawing and List,
Models 224741, and 224742 22. . . . . . . . . . . . . . . . .
Displacement Pump Repair, Model 237653 23. . . .
Reciprocator Parts Drawing/List,
Model 237653 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Parts Drawing and List,
Model 237653 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and Mounting Hole Layout 27. . . . . . . .
Graco Standard Warranty 28. . . . . . . . . . . . . . . . . . .
Graco Phone Number 28. . . . . . . . . . . . . . . . . . . . . . .
Parts

2 308155
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the corresponding
instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding 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 you operate the equipment.
DUse the equipment only for its intended purpose. If you are not sure, 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 component in your system.
Check the Technical Data section on page 26 for the maximum hydraulic input pressure and the
maximum fluid outlet pressure of your pump model.
DUse fluids and solvents that are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
DDo not kink or overbend hoses or 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).
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNING
WARNING

308155 3
TOXIC FLUID HAZARD
Hazardous fluids 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.
FLUID INJECTION HAZARD
Fluid from the dispensing valve, leaks or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate sur-
gical treatment.
DDo not point the dispensing valve at anyone or at any part of the body.
DDo not put your hand or fingers over the end of the dispensing valve.
DDo not stop or deflect leaks with your hand, body, glove, or rag.
DUse only extensions and couplers that are designed for use with your dispensing valve.
DDo not use a low pressure flexible nozzle with this equipment.
DFollow the Pressure Relief Procedure on page 9 if the grease fitting coupler clogs and before
cleaning, checking, or servicing the equipment.
DTighten all fluid connections before you operate the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do
not repair high pressure couplings; you must replace the entire hose.
DFluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
WARNING
WARNING

4 308155
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of all moving parts when you start or operate the pump.
DBefore you service the equipment, follow the Pressure Relief Procedure on page 9 to prevent
the equipment from starting unexpectedly.
WARNING
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 dispensed to. Refer to Grounding on page 8.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop
dispensing 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 dispense area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispense area.
DDo not turn on or off any light switch in the dispense area while dispensing or while operating if
fumes are present.
DKeep a fire extinguisher in the work area.

308155 5
Installation
Fig. 1
KEY
ASuction hose
BWeep tube
CFluid outlet line (to gun)
DDrain valve (required)
EGround wire
FHydraulic return line, minimum
3/4” I.D. (required)
GHydraulic outlet, 1/2 npt
HReturn line shut-off valve,
minimum 3/4” (required)
JHydraulic inlet, 1/2 npt
KTee, 3/4 npt
L* Supply line shut-off valve
M* Pressure gauge
N* Pressure reducing valve
(required in systems over 1500
psi [10 MPa, 102 bar])
PAccumulator
Q* Flow control valve
(required in systems over 3 gpm
[11 lpm])
RHydraulic supply line
SCheck valve
TVariable volume pressure
compensated pump
UHydraulic power supply
WDrain line, accumulator
XLow-level cut-off valve
YThermal Relief Kit (required)
Part No. 237904
Typical Installation of a
Suction Feed System
A
BC
D
EFGHJKLMN
P
Q
R
ST
U
W
*Included in Hydraulic Fluid Control Kit 236864, which can be ordered separately.
X
Y
01843
Although the installation shown in Fig. 1 is only a guide for selecting and installing system components and
accessories, some of the equipment is required, as noted in the key. For assistance in designing a system to suit
your needs, contact your Graco distributor.
Mount the pump to suit the type of installation planned.

6 308155
Installation
WARNING
Mount the pump securely so that it cannot move
around during operation. Failure to do so could
result in personal injury or equipment damage.
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 or the pump fluid outlet side must have
at least a 1500 psi (10 MPa, 102 bar) maximum
working pressure for models 239882, 224741, and
224742, and at least a 1000 psi (7 MPa, 69 bar)
maximum working pressure for model 237653.
WARNING
Pump Accessories
DA suction hose kit (A ) , Part No. 236054, is
available for siphoning from 55 gallon
containers.
DIntake tube (not shown). To install, apply
Rtape to the female threads at the top
of the tube. Screw the tube tightly into the
intake housing of the stubby pump.
DLow-level cut-off valve (X), Part No. 203688,
closes the pump intake when the fluid level is
low, causing the pump to stall to avoid running
dry. To install, screw the valve into the bottom
of the pump intake tube or the suction tube.
DA pump outlet drain valve (D), Part No.
210658, is installed close to the pump fluid
outlet to help relieve fluid pressure in the pump
when the pump is shut off.
DThermal Relief Kit (Y), Part No. 237904.
Install at the pump fluid outlet.
WARNING
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. In-
stall the valve close to the pump outlet.
Keep The Hydraulic System Clean
The hydraulic supply system must be kept clean at
all times to reduce the risk of damaging the recip-
rocator hydraulic power supply. Blow out all hy-
draulic 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 changing the hydraulic fluid.
CAUTION
Hydraulic Power Supply
Limit Fluid Flow to Reciprocator
To reduce the risk of overpressurizing 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 MPa, 102 bar). See
the description below.
WARNING
The hydraulic power supply system (U) must have a
pressure reducing valve and a pressure-compensated
flow control. A flow control valve (Q) 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 (Q) are included in the Hydraulic Fluid Control Kit
236864, which can be ordered separately.
PTFE

308155 7
Installation
Hydraulic Lines
NOTE: Refer to Fig. 1 to locate the parts mentioned
below.
DShut-off valves (H and L) are installed in the
hydraulic supply and return lines. Order Part No.
108458 for 1/2 npt(f) supply lines and 108537 for
3/4 npt(f) return lines.
DDrain Line. Remove the plug (59) from the pump
adapter, and install a 1/8–27 npt(f) tube fitting and
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.
See Fig. 2.
Fig. 2
59
06146C
DHoses. Use a minimum 1/2” supply line (R) and
minimum 3/4” return line (F) on the reciprocator.
Contact your Graco representative for details of line
sizing.
DA 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 (W) teed into the hydraulic
return line (F). Limit supply pressure to a maximum
of 1500 psi (10 MPa, 102 bar).
DAn accumulator (P) reduces the hammering effect
caused by the motor when it reverses direction.
DA fluid-filled pressure gauge (M), Part No.
112567,monitors hydraulic pressure to the
reciprocator during startup. See Fig. 1. Use the
gauge for initial adjustment of the reciprocator. It
can be removed after adjustment is made.

8 308155
Installation
Grounding
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.
DPump: Use ground wire and clamp as shown in Fig.
3.to the right. To order a Grounding Wire and
Clamp Kit, order Part No. 222011.
DHydraulic Hoses and Fluid Outlet Hoses: Use only
electrically conductive hoses.
DHydraulic Power Supply:
Follow manufacturer’s recommendations.
DAny pails used when flushing: Use only metal,
grounded pails when flushing. Make firm
metal-to-metal contact between the a 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. See Fig. 3.
To order a ground wire and clamp, order Part No.
222011.
Fig. 3
Y
06147C
Z

308155 9
Operation
Pressure Relief Procedure
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or dispensing accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you
DAre instructed to relieve the pressure
DCheck or service any of the system equipment
DInstall or clean the nozzle
WARNING
1. Shut off the hydraulic power supply.
2. Close the supply line shut-off valve (L in Fig. 1).
3. Open the dispensing valve to relieve pressure.
4. Open the pump outlet drain valve, and have a
container ready to catch the drainage.
5. Close the return line shut-off valve (H).
NOTE: 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 relieved
after following the steps above, very slowly loosen the
hose end coupling to relieve pressure, then clear the
obstruction.
Before You Start 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.
CAUTION
Always use Graco approved hydraulic oil or equiv-
alent, Part Numbers 169236 (5 gallon) or 207428
(1 gallon). Do not substitute lower grade oil.
2. Flush the pump before you use it for the first time
to remove the light oil that was left in after factory
testing 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 on page 26. 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 (Q) to limit the
hydraulic flow to no more than 3 gpm (11 lpm),
which is approximately 60 cycles per minute.
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 MPa, 3.4 to 102 bar) for models
239882, 224741, and 224742. Increasing the inlet
pressure increases the outlet pressure.
Decreasing the inlet pressure decreases the outlet
pressure.
NOTE: For model 237653, adjust the hydraulic
inlet pressure from 50 to 1000 psi (0.34 to 7 MPa,
3.4 to 69 bar).
5. 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 off the power
supply to the reciprocator immediately. Refill the
supply container, and prime the pump to eliminate
air.
To prevent the pump from running dry, use a low-
level cutoff valve (X). See Fig.1 on page 5.
CAUTION
CAUTION
Maximum Working Temperature
Do not exceed 130_F (54_C) hydraulic oil tem-
perature. The reciprocator seals will wear faster
and leakage may occur if the pump is operated at
higher oil temperatures.

10 308155
Operation
Maximum Working Pressures
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:
DFor models 239882, 224741, and 224742,
never exceed 1500 psi (10 MPa, 102 bar)
Maximum Hydraulic Pressure to the
reciprocator or Maximum Outlet Pressure from
the displacement pump.
DFor model 237653, never exceed 1000 psi
(7 MPa, 69 bar) Maximum Hydraulic Pressure
to the reciprocator or Maximum Outlet Pressure
from the displacement pump.
DBe sure all accessories added to the
reciprocator power supply side or the pump fluid
outlet side have at least a 1500 psi (10 MPa,
102 bar) Maximum Working Pressure for
models 239882, 224741, and 224742;and at
least a 1000 psi (7 MPa, 69 bar) Maximum
Working Pressure for model 237653.
DThe maximum working pressure of the
displacement pump is directly proportional to
the pressure at which the reciprocator is
operated. Therefore, if the fluid supplied to the
reciprocator is 1000 psi (7 MPa, 69 bar), the
pump fluid outlet pressure will also be 1000 psi
(7 MPa, 69 bar).
WARNING
Shutdown
Relieve the pressure whenever you shut down.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
If the Pump Leaks at the Fluid Fittings
Fig. 4
04478
self-sealing fitting
(1,5,58)
o-ring
reciprocator
Models 239882, 224741, and 224742: Tighten
the fittings (1, 5, 58), which are self-sealing and
have replaceable o-rings. If leaking persists,
change the o-rings.
Model 237653: Tighten the fittings (B or K).
These fittings are self sealing and have
replaceable o-rings. If leaking persists, change
the o-rings.
self-sealing
fitting (B or K)
reciprocator
o-ring

308155 11
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
Note: Check all possible problems and solutions
before disassembling the pump or reciprocator.
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
obstructions.
Reciprocator damaged. Repair. See page 14.
Pump speeds up or runs erratically. Pump piston and/or intake
valve worn.
Relieve pressure. Check and repair.
See page 20.
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.
See page 20.
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.
Relieve 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.

12 308155
Service
Replacing the Throat Seals
See Fig. 5.
NOTE: Replace these seals if fluid leaks excessively
through the weep tube (B). This procedure can be
done without disassembling the entire reciprocator.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
1. Relieve the pressure.
2. Disconnect the reciprocator from the pump. See
the procedure 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).
NOTE: Items 16 and 44 are included in the
Reciprocator Repair Kit, 223426.
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-lb (38 to 43 N.m). Install the displacement
pump. Follow Step 24, page 17. Fig. 5 01660
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.
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
whenever fluid lines are disconnected to prevent
contamination.

308155 13
Service
Disconnecting the Reciprocator and
Displacement Pump
Models 239882, 224741, and 224742
1. Flush the pump if possible, and stop it with the
displacement rod in the lowest position.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
2. Relieve the pressure.
3. Disconnect the outlet hose from 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
fittings, and replace them if they are worn or
damaged. 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 (117) down as far as it will
go. Remove the cotter pin (118) from the bottom of
the displacement rod assembly (34), and unscrew
the connecting rod until it is free.
Model 237653
1. Flush the pump if possible, and stop it with the
displacement rod in the lowest position.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
2. Relieve the pressure.
3. If you remove the pump from its mounting,
disconnect the hydraulic hoses, and plug all
hydraulic connections and lines to prevent
contamination.
4. Remove the cotter pin (A) from the top of the
displacement rod (B).
5. Loosen and remove the three locknuts (C), and
pull the displacement pump down and away from
the motor.
6. Unscrew the displacement rod (B) from the
reciprocator connecting rod (D).
Fig. 6
01662
43
36,37
33
32
117
103
118
108
46 (hidden from view)
34
06143B
Models 239882, 224741, and 224742
Model 237653
03834
A
B
C
D

14 308155
Service
Reciprocator Repair
NOTES
DThe following reciprocator repair instructions are for
Models 239882, 224741, and 224742. For Model
237653 instructions, see accompanying manual
307654.
DClean 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
available. Parts included in the kit are marked with
one asterisk, for example (23*), in the text and
drawings. Always replace the seals (23*, 24*) and
the seals (16*, 44*) together.
DAssembly Tool 189305 is required for
reassembling the reciprocator.
DLoctiter242 thread sealant and LoctiterPrimer T
or Perma-Locr115 thread sealant and
Perma-BondrSurface Conditioner I are required.
Be sure their shelf life is within the manufacturer’s
recommendations.
Note: Use Loctiter609 on yoke (9) and rod (12) on
page 15, step 9 only. Use Loctiter242 or
Perma-Locr115 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 of the adapter. See Fig. 7. If needed,
replace the seals as described on page 12.
2. Remove the capscrew (3), nuts (36), and
lockwashers (37) on top of the reciprocator. See
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
prevent contamination. See Fig. 4 and the Parts
Drawing.
See Fig. 9 for Steps 4 to 13, except where noted.
Fig. 7
43
36,37
33
32
3,39,2
46
(hidden from
view)
06146C
4. Tap on the bottom of the displacement rod (34)
with a plastic mallet to loosen the cylinder (25).
5. 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 rods from the bottom cap.
6. 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.
7. 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
the piston (22) to screw it off the rod.
CAUTION
Be careful not to scratch the outside of the dis-
placement rod or the inside of the cylinder.

308155 15
Service
8. 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 shoulder of the rod. See Fig. 8.
Fig. 8
20
21
20
01664
18
12
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).
NOTE: Thread sealant and primer are required. See
Reciprocator Repair Notes on page 14 for
specifications. Loctiter609 is used only in step below.
9. Apply fresh Loctiter609 thread sealant to the first
two or three internal threads of the yoke (9). Apply
primer to the external thread of the rod (12). Let
dry for three or four minutes. Assemble, torquing
the screw to 54 to 56 in-lb (6.1 to 6.3 N-m).
Remove excess sealant. Allow 24 hours to cure
before operating the reciprocator.
10. Clean all sealant from the threads of any part you
are reusing, and apply thread sealant to the first
two or three internal threads of the valve assembly
(31). If you removed the capscrew (51), apply
primer to its external threads, let it dry for four
minutes, and torque the capscrew to 42 to 45 in-lb
(4.7 to 5.1 N-m). Remove excess sealant. Allow 24
hours for the thread sealant to cure before you
operate the reciprocator.
11. Remove the o-ring (13*) from the bottom of the
spool valve assembly (31), and replace it with a
new o-ring.
12. Use a spanner wrench to screw the piston (22)
onto the displacement rod (34). Torque to 30 to 40
ft-lb (41 to 54 N.m).
Fig. 9
34
17
12
38
36,37
31
29
32
22
20
21
18
51
*13
6,7
9
17
25
34
20
13*
*24
23*,49*
3,39,2
30
1
See
Fig. 8
1
2
Torque to 30 to 40 ft-lb (41 to 54 N.m)
2
06145
Apply thread adhesive, and torque to 42 to 45
in-lb (4.7 to 5.1 N-m).
26

16 308155
Service
Fig. 10
31
ASSEMBLY B
26
6
7
9
29
12
ASSEMBLY A
C
D
06148
13. Lay Assembly A and Assembly B on the
workbench.
14. Slide Assembly B into the center of the tool (D),
Part No. 189305. Align the upper detent holes (C)
of the guide yoke (9) with the center line of the tool
(D). See Fig. 10.
15. Insert the spring (6) and one ball (7) into the valve
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 assembly
together. See Fig. 10.
16. 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. See Fig. 10. Slide the tool (D)
back over the rod (12) to remove it.
In steps 18 through 26, see Fig. 11.
17. Place the adapter (43) in a vise, and install the
seals as described on page 12. Install the cylinder
cap (32).
18. 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).
19. 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.
CAUTION
When you insert the piston into the cylinder, care-
fully guide the piston seal (23*) and bearing (24*)
to prevent damaging them.

308155 17
Service
20. Place the cylinder (25) on the cylinder cap (32).
Install the piston (22) and valve assembly (31).
NOTE: When you reinstall the cylinder (25), be sure
the “P” port in the top cylinder cap of the spool valve
assembly (31) and the port in the bottom cylinder cap
(32) are in line with each other. Be sure the o-rings
(13*) are in place in the valve spool assembly (31) and
cylinder cap.
21. 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-lb (36 to 43 N.m).
CAUTION
Never install the fluid tube (45) before you torque
the tie rods. Doing so could cause misalignment
and damage the reciprocator when it is operated.
22. Reinstall the fluid tube (45) and fittings (1). Torque
the fittings to 25 to 35 ft-lb (34 to 48 N.m). See the
Parts Drawing on page 18.
23. Pull the displacement rod (34) in and out to be
sure it moves easily
24. Grease the inside top of the displacement cylinder
(108) opening. Thread the guide collar, Part No.
168085, onto the displacement cylinder. Slide the
packing assembly into the collar/cylinder. See Fig.
14. Remove the guide collar.
25. To reconnect the reciprocator and pump, screw the
connecting rod (117) into the displacement rod
(34). Install the cotter pin (118). Make sure the
o-ring (119) 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.
See Fig. 12.
26. Connect the hydraulic supply and return hoses to
the fittings (5, 60).
WARNING
To reduce the risk of static sparking be sure to re-
connect the ground wire before operating the
pump.
Fig. 11
36,37
31
32
*13
25
13*
3,39,2
43
34
38
1
1
Torque to
28 to 32 ft-lb
(36 to 43 N.m).
06145
Fig. 12 01662
117
103
118
34
108
119*
43

18 308155
Reciprocator Parts Drawing
Model 239882, Series A, Hydraulic Reciprocator
34a
34b
34c
49*
38
46
52
33
Ref 46
43
*44
19
*16
32
18
20
21
20
22
*13
9
26
29
31
37
36
24*
23*
*4
51
25
17
5
NOTE: See pages 12 to 20 for
important assembly
procedures and torque
values.
59
40
label
45
58
7
6
1
14
5a
1a
58a
12
3
39
2
30
60 *16
*13
06144B
7

308155 19
Reciprocator Parts List
Model 239882, Series A, Hydraulic Reciprocator
Ref.
No. Part No. Description Qty.
Ref.
No. Part No. Description Qty.
1 106470 ELBOW, straight thread,
3/4–16 unf–2a x
3/4–16 unf–2a, 37_flare
includes item 1a 1
1an110987 .O-RING 1
2 178179 WASHER, sealing 1
3 106276 CAPSCREW, hex hd,
3/8–24 x 5/8” 1
4* 104093 O-RING, nitrile rubber 1
5 112568 ADAPTER, pipe,3/4 npt(f) 1
6 108437 SPRING, compression, steeL 1
7 100069 BALL, 1/4” dia. steel 2
9 189077 YOKE, valve 1
12 192657 ROD, stop, cs 1
13* 106274 O-RING, buna–N 2
14 116343 SCREW, grounding 1
16* 108952 PACKING, v-block 2
17 105765 O-RING 1
18 114231 LOCKNUT, hex, 1/4–28 unf–3b
steel & nylon 1
19 183531 GUIDE, rod, bronze 1
20 192655 RETAINER, spring, cs 2
21n178189 SPRING, compression, steel 1
22 192656 PISTON, cs 1
23* 178226 SEAL, piston
glass-filled R1
24* 178207 BEARING, piston
bronze-filled R1
25 178229 CYLINDER, motor, cs 1
26 192654 STOP, valve, cs 1
29 192654 SLEEVE, valve, steel 1
30 178181 PLATE, cap 1
31 239874 SPOOL VALVE ASSEMBLY 1
32 186225 CAP, cylinder, bottom, cs 1
33 183833 BASE, aluminum 1
34 222301 DISPLACEMENT ROD ASSY.
Contains 34a to 34c
34a 188078 ROD, displacement 1
34b 105765 PACKING, o-ring 1
34c 178232 STOP, displacement rod 1
36 100307 NUT, full, hex, 3/8–16 unc–2b 4
37 100133 LOCKWASHER, 3/8” 4
38 187405 ROD, tie, 8.5” shoulder to
shoulder, 3/8–16 unc–2a,cs 4
39 155685 O-RING
40Y179885 LABEL, Warning 1
43 183533 ADAPTER, pump, cs 1
44* 108951 SEAL, polyester elastomer 1
45 217221 TUBE, inlet 1
46 108986 CAPSCREW, sch; 3/18–16
unc–2a x 4.5” 4
49* 108014 O-RING, buna–N 1
51 104092 CAPSCREW, sch; 10–24
unrc–3a x 5/8” 2
52 106115 LOCKWASHER, spring, 3/8” 4
58 107197 TEE
Includes item 58a 1
58an110987 .O-RING 1
59 110064 PLUG, pipe, vented, 1/8–27 nptf 1
60 112569 UNION, swivel; steel 1
* These parts are included in Repair Kit 223426,
which may be purchased separately. The Repair Kit
also includes item No. 119, shown on page 22.
nKeep these spare parts on hand to reduce
downtime.
YReplacement Danger and Warning labels, tags, and
cards are available at no cost.
Assembly Tool 189305 required for repairing the
reciprocator.
PTFE
PTFE

20 308155
Displacement Pump Repair
(Models 239882, 224741, and 224742)
Intake Valve. See Fig. 13.
WARNING
To reduce the risk of serious injury, whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
1. If possible, flush the pump. Relieve the pressure.
2. Unscrew the valve body (110). Remove the o-ring
(111), ball (109), and retainer (112).
3. Inspect the parts for wear or damage. If the ball is
nicked, replace it. Reassemble, using liquid thread
sealant on the male threads.
Displacement Pump. See Fig. 13.
NOTE: 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 disassemble the pump. The parts
list on page 22 gives the recommended parts to keep
on hand.
A guide collar is required for installing the piston in the
displacement cylinder. Order Guide Collar Tool, Part
No.168085, or make a collar using shim stock having a
0.016 in. (0.41 mm) maximum thickness.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 9.
1. If possible, flush the pump. Relieve the pressure.
2. Remove the intake valve. Follow Disconnecting
the Reciprocator and Displacement Pump
procedure on page 13.
3. Carefully inspect the smooth, inner surface of the
cylinder (108) for scoring or irregular surfaces.
Such damage causes premature packing wear and
leaking, so replace the part if needed.
4. Place the piston housing (104) in a vise. Unscrew
the piston seat (107), and remove the packings.
5. Grease the new piston packings, and stack them
one at a time on the piston seat (107), making
sure all parts face the way shown in Fig. 13. Install
the ball (116). Apply liquid sealant to the male
threads of the seat (107), and screw on the piston
housing (104).
6. Remove the ball retainer (112) from the intake
housing assembly by grabbing the open leg and
pulling it toward the center of the housing. Inspect
the ball (109) and seat, and replace as needed.