Graco Dyna-Star 239882 User manual

Instructions
Dyna-Star™Hydraulic
Reciprocator and Pump 308155U
EN
For lubricating fluids only. For professional use 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 Pres-
sure
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 Pres-
sure
Model 237653, Series B,
Stainless Steel Stubby Length Pump
1000 psi (7 MPa, 70 bar) Maximum Hydraulic Input
Pressure
1000 psi (7 MPa, 70 bar) Maximum Fluid Outlet Pres-
sure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.

Warnings
2308155U
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
308155U 3
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
component. 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
4308155U
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 rec-
ommendations.
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
308155U 5
Key:
A Suction hose
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
X Low-level cut-off valve
Y Thermal Relief Kit (required)
* 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
BC
D
EFGH
JKLMN
P
R
S
TU
V
W
X
Y

Installation
6308155U
Pump Accessories
• A suction hose kit (A) is available for siphoning from
55 gallon containers.
• Intake tube (not shown). To install, apply PTFE tape
to the female threads at the top of the tube. Screw
the tube tightly into the intake housing of the stubby
pump.
• Low-level cut-off valve (X) 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.
• A pump outlet drain valve (D) is installed close to
the pump fluid outlet to help relieve fluid pressure in
the pump when the pump is shut off.
• Thermal relief kit (Y). Install at the pump fluid outlet.
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
changing 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.
Mount the pump securely so that it cannot move
around during operation. Failure to do so could result
in personal injury or equipment damage.
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
308155U 7
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 (W): 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 reciproca-
tor/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 (W) 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
8308155U
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Shut off the hydraulic power.
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 nec-
essary 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 25. 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) 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 7
bar).
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
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.
To prevent the pump from running dry, use a
low-level cut off valve (X).

Operation
308155U 9
Shutdown
Relieve the pressure whenever you shut down. See
Pressure Relieve Procedure on page 8.
If the Pump Leaks at the Fluid
Fittings
Models 239882, 224741, and 224742: Tighten the fit-
tings (1, 5, 58) which are self sealing and have replace-
able o-rings. If leaking persists, change the o-rings. (FIG.
4)
9
Model 237653: Tighten fittings (B or K). These fittings
are self sealing and have replaceable o-rings. If leaking
persists, change the o-rings. (FIG. 5)
FIG. 4
self-sealing
fitting (1,5,58)
o-ring
(1a,5a,58a)
reciprocator
FIG. 5
self-sealing
fitting (B or K)
reciprocator
o-ring

Troubleshooting
10 308155U
Troubleshooting
1. Follow Pressure Relief Procedure, page 8, 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 11.
Pump speeds up or runs erratically
Pump piston and/or intake valve is
worn
Relieve pressure. Check and repair.
See page 11
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 11.
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 11.
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
308155U 11
Repair
Replacing the Throat Seals
Refer to FIG. 6 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 8.
2. Disconnect the reciprocator from the pump. See
Disconnecting the Reciprocator and Displacement
Pump on page 12.
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. 6.
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 17.
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. 6
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
12 308155U
Disconnecting the Reciprocator
and Displacement Pump
Refer to FIG. 7 for the following instructions.
Models239882, 224741, and 224742
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 8.
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 FIG. 5 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 dis-
placement rod in the lowest position.
2. Relieve the pressure, see Pressure Relief Proce-
dure, page 8.
3. If the pump is removed the its mounting, disconnect
the hydraulic hoses, and plug all hydraulic connec-
tions and lines to prevent contamination.
4. Remove the cotter pin (A) from the top of the dis-
placement rod (B).
5. Loosen and remove the three lock nuts (C), and pull
the displacement pump down and away from the
motor.
6. Unscrew the displacement rod (B) from the recipro-
cator connecting rod (D).
FIG. 7
43
36,37
33
32
117
103
118
108
46 (hidden from view)
34
Models 239882, 224741, and 224742
A
B
C
D
Model 237653

Repair
308155U 13
Reciprocator Repair
NOTE:
• The following reciprocator repair instruction are for
models 239882, 224741, and 224742. For Model
237653 instructions, see accompanying manual
307654.
• 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.
NOTE: Use Loctite®609 on yoke (9) and rod (12) on
page 14, step 9 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. 8. If needed,
replace the seals as described in Repair on page
11.
2. Remove the capscrew (3), nuts (36), and lockwash-
ers (37) on top of the reciprocator. (FIG. 8)
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 and FIG. 5)
NOTE: See FIG. 10 for Steps 4 to 12, except where
noted.
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 rod 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 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.
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
FIG. 8
43
36,37
33
32
3,39,2
46
(hidden from
view)

Repair
14 308155U
(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. 9)
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 9.
9. 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 96 to 100 in-lbs (10.8 to 11.2 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 capscrews to 42 to 45 in-lbs (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-lbs
(41 to 54 N.m).
FIG. 9
20
21
20
18
12
FIG. 10
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
308155U 15
13. Lay Assembly A and Assembly B on the work
bench. (FIG. 11)
14. 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. 11)
15. 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. 11)
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. (FIG. 11) Slide the tool (D) back over
the rod (12) to remove it.
17. Place the adapter (43) in a vise, and install the seals
as described on page 11. Install the cylinder cap
(32). (FIG. 13)
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). (FIG. 13)
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. (FIG. 13)
20. Place the cylinder (25) on the cylinder cap (32).
Install the piston (22) and the valve assembly (31).
(FIG. 13)
NOTE: When the cylinder is reinstalled, 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-lbs (36 to 43 N.m).
FIG. 11
31
ASSEMBLY B
26
6
7
9
29
12
ASSEMBLY A
C
D
NOTICE
When inserting the piston into the cylinder, carefully
guide the piston seal (23) and bearing (24) to prevent
damaging them.

Repair
16 308155U
22. 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.
23. Pull the displacement rod (34) in and out to be sure
it moves easily. (FIG. 13)
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. Remove
the guide collar. (FIG15)
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. (FIG. 12)
26. Connect the hydraulic supply and return hoses to
the fittings (5, 60).
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.
FIG. 12
To reduce the risk of static sparking be sure to
re-connect the ground wire before operating the
pump.
117
103
118
34
108
119*
43
FIG. 13
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
308155U 17
Displacement Pump Repair
(Models 239882, 224741, and
224742)
Intake Valve
Refer to FIG. 14.
1. If possible, flush the pump. Relieve the pressure,
see Pressure Relief Procedure, page 8.
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
Refer to FIG. 14.
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 X give the recommended parts to keep on
hand.
A guide collar is required for installing the piston in the
displacement cylinder. Order Guider Collar Tool (Part
No. 168085) or make a collar using shim stock having a
0.016 inch (0.41 mm) maximum thickness.
1. If possible flush the pump. Relieve the pressure.
See Pressure Relief Procedure, page 8.
2. Remove the intake valve. Follow Disconnect the
Reciprocator and Displacement Pump procedure on
page 12.
3. Carefully inspect the smooth, inner surface of the
cylinder (108) for scoring or irregular surfaces. Such
damage causes premature packing wear and leak-
ing, replace the part as 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. 14. 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 hous-
ing 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.
Intake Valve Reassembly
1. Grease the inside top of the displacement cylinder
(108) opening. Thread the guide collar onto the dis-
placement cylinder. Slide the packing a assembly
into the collar/cylinder. See FIG. 15. Remove the
collar guide.
FIG. 14
117
103
104
116
115
114
114
106
114
107
115
108
112
109 111
110
118
119
105
0.2 ”
(5 mm)

Repair
18 308155U
NOTE: If you removed or turned the next nut (103),
check the ball travel. It should be 0.2 inches (5 mm), as
shown in FIG. 14.
2. 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 he pump, using a
strap wrench for the final tightening. (FIG. 14)
3. Reinstall the intake valve assembly by doing the
reverse of Step 6 of the section Displacement
Pump.
Displacement Pump Repair
(Model 237653)
Disassembly
When disassembling the pump, lay out all removed
parts in sequence to ease reassembly.
NOTE: Clean all parts thoroughly when disassembling.
Check them carefully for damage or wear, replacing
parts as needed.
1. Remove the displacement pump from the reciproca-
tor. See page12 for instructions on removing.
2. Unscrew the locking ring (17) from the cylinder (11).
Remove the intake valve housing (13).
3. Remove the o-ring (12), ball stop pin (5), ball guide
(22), and ball (2) from the intake valve housing (13).
4. Loosen the packing nut (15). Push the displacement
rod (7) down as far as possible, then pull it out the
bottom of the cylinder (11).
5. Secure the flats of the piston (14) in a vise. Using a
wrench on the flats of the piston mounting stud (28),
screw the piston stud off the piston.
6. Remove the piston packings (25, 26), glands (24,
27), shim (29), and washer (23).
7. Remove the packing nut (15), throat packings (9,19)
and glands (6,8) from the outlet housing (16).
8. Inspect all parts for damage. Clean all parts and
threads with a compatible solvent before reassem-
bling. Inspect the polished surfaces of the displace-
ment rod (7) and cylinder (11) for scratches, scoring
or other damage, which can cause premature pack-
ing wear and leaking. To check, run a finger over
the surface or hold the part up to the light at an
angle. Be sure the ball seats of the piston (14) and
intake valve housing (13) are not chipped or nicked.
Replace any worn or damaged parts.
Reassembly
1. Lubricate the throat packings and install them in the
outlet housing (16) one at a time as follows, with the
lips of the v-packings facing down: the male gland
(6), two neoprene v-packings (9), one UHMWPE
v-packing (19), and the female gland (8). Apply
thread lubricant and install the packing nut (15)
loosely.
2. Lubricate the piston packings and install them onto
the piston stud (14) one at a time in the following
order, with the lips of the v-packings facing up: the
female gland (27), one UHMWPE v-packing (25),
one neoprene v-packing (26), one UHMWPE
v-packing (25), the male gland (24), the shim (30),
and the washer (23).
3. Place the flats of the displacement rod (7) in a vise
and screw the piston stud (14) onto the displace-
ment rod. Torque to 50 to 70 ft-lbs (68 to 95 N.m).
4. Slide the ball stop pin (10) into the desired set of
holes and secure with the new cotter pins (1). Install
the piston ball (2) in the piston mounting stud.
5. Screw the piston stud (14) onto the piston mounting
stud (28). Torque to 50 to 70 ft-lbs (68 to 95 N.m).
FIG. 15
117
104
168085
guid
e collar
108

Repair
308155U 19
6. Insert the displacement rod (7) into the top of the
cylinder (11), being careful not to scratch the cylin-
der. Insert only until the packings are in the cylinder.
7. Lubricate the o-ring and apply thread lubricant to the
cylinder, then reinstall the cylinder in the outlet
housing (16).
8. Install the ball (2), guide (22), o-ring 12), and ball
stop pin (5) in the intake valve housing (13). Place
the intake valve assembly in the cylinder (11). Apply
thread lubricant to the locking ring and cylinder (11),
and screw the ring onto the cylinder.
9. Reconnect the displacement pump to the reciproca-
tor by performing the reverse of the disassembly
procedure on page 12. (FIG. 7)

Parts
20 308155U
Parts
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
59
40
label
45
58
7
6
1
14
5a
1a
58a
12
3
39
2
30
60 *16
*13
7