Graco Dyna-Star 25A189 Use and care manual

3A3005C
Instructions, Repair and Parts
Dyna-Star®
Hydraulic Reciprocator and
High Pressure Pump
High Pressure Pump and Reciprocator used for dispensing grease in wire-
line applications for oil well services.
900 psi (6.2 MPa, 62.1 bar)) Maximum Hydraulic Input Pressure
10,000 psi (69 MPa, 689 bar) Maximum Fluid Outlet Pressure
Model 25A189: 120 lb Drum Length
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
EN

Warnings
23A3005C
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
WARNINGWARNING
SKIN INJECTION HAZARD
High-pressure fluid from 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 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.
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.
• Ground all equipment in the work area.
• Keep work area free of debris, including rags and spilled or open containers of solvent and gas-
oline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• 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.

Warnings
3A3005C 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 Safety Data Sheet (SDS) from distributor or retailer.
• 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 man-
ufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre-
ate 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.
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 equip-
ment, follow the Pressure Relief Procedure and disconnect all power sources.
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 Safety Data Sheet (SDS) 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.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, includ-
ing eye injury, hearing loss, inhalation of toxic fumes, and burns. 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 manufac-
turer.
WARNING
WARNINGWARNING

Installation
43A3005C
Installation
Typical Installation
The following Typical Installation is only provided as a guide for selecting and installing system components and
accessories. Mount pump to suit the type of installation planned. For assistance in designing a system to suit your
needs, contact your Graco Distributor.
Key:
A Drain line
B Weep tube
C Fluid outlet line
D Drain valve (required)
E Ground wire
F Hydraulic return line, minimum 3/4 inch I.D. (required)
G Hydraulic outlet, 3/4” NPT (f)
H Return line shut-off valve, minimum 3/4 inch (required)
J Hydraulic inlet, 3/4” -16 JIC (37° flare)
L Supply line shut-off valve (required)
M Pressure gauge
N Pressure reducing valve (required in systems over 900 psi
[6.2 MPa, 62.1 bar)])
P Accumulator
R Flow control valve (required in systems over 3 gpm [11
lpm])
S Hydraulic supply line
TCheckvalve
U Variable volume pressure compensated pump
V Hydraulic power supply
WCheckvalve
Y Pressure gauge
ZCheckvalve
AA Shut-off valve
BB Drain tube
CC 1/2 NPT outlet adapter (included)

Installation
3A3005C 5
Installation Instructions
Pump Accessories
Pump Outlet Drain Valve (D): helps relieve fluid pres-
sure in pump when pump is shut off. Install valve close
to pump fluid outlet.
Pump Outlet Adapter (CC): pump is supplied with an
adapter to female 1/2 NPT. To connect directly to pump,
remove the adapter and use a medium 3/16-16 UN
medium pressure, coned and threaded connection.
Hydraulic Power Supply
See Typical Installation, page 4.
The hydraulic power supply (V) must have a pressure
reducing valve and a pressure-compensated flow con-
trol.
A flow control valve (R) is required to limit the incoming
flow to the reciprocator to a maximum of 3 gpm (11 lpm).
Hydraulic Lines
Shut-off Valves (H, L): installed on the hydraulic supply
and return lines. Order Part No. 108537 and 112578.
Drain Line: Monitor the weepage of hydraulic fluid or
lubricant. If it seems excessive or increases suddenly,
the reciprocator/pump seals may need to be changed.
Hoses: Use a minimum 1/2 inch supply line (S) and
minimum 3/4 inch return line (F) on the reciprocator.
Contact your Graco representative for details of line siz-
ing.
Pressure Reducing Valve (N): circulates excess
hydraulic fluid pressure back to the hydraulic power sup-
ply. Install this valve (N) in the hydraulic supply line with
a drain hose (A) teed into the hydraulic return line (F).
Limit supply pressure to a maximum 900 psi (6.2 MPa,
62.1 bar)).
Accumulator (P): reduces hammering effect caused by
the reciprocator when it reverses direction.
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.
Mount pump securely so it cannot move around
during operation. Failure to do so could result in per-
sonal injury and/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 component ruptures, all
accessories added to the reciprocator power supply
side must have at least 900 psi (6.2 MPa, 62.1 bar))
maximum working pressure.
All accessories added to the pump fluid outlet side
must have at least 10,000 psi (69 MPa, 689 bar)
maximum working pressure.
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, a hydraulic system
must have a means to limit the incoming fluid flow to
the reciprocator to a maximum of 3 gpm (11 lpm) and
900 psi (6.2 MPa, 62.1 bar).

Installation
63A3005C
Grounding
•Pump: Use ground wire and clamp as shown in
FIG. 1. Order Grounding Wire and Clamp Kit,
Part No. 222011.
•Hydraulic Hoses and Fluid Outlet Hoses:
Use electrically conductive hoses only.
•Hydraulic Power Supply: Follow manufac-
turer’s recommendations.
•Flushing Pails: When flushing, only use metal,
grounded pails. Make firm, metal-to-metal con-
tact between the metal part of the dispense
valve and the pail. Use lowest possible pres-
sure.
Grounding the Pump (FIG. 1)
To ground pump:
1. Remove ground screw (Z) and insert through eye of
ring terminal at end of ground wire.
2. Fasten ground screw back onto pump and tighten
securely.
3. Connect other end of wire to the frame of the truck.
The equipment must be grounded to reduce the risk
of static sparking. Static sparking can cause fumes to
ignite or explode. Grounding provides an escape wire
for the electric current.
FIG. 1
Z

Operation
3A3005C 7
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Turn off hydraulic power supply (V).
2. Close supply line shut-off valve (L).
3. Open pump drain valve (D).
4. Verify pressure has been relieved by checking pres-
sure gauge (Y).
5. Close shut-off valve (AA).
NOTE: Leave the drain valve (D) open until you are
ready to dispense again.
Before Starting Pump
• Check hydraulic fluid level in hydraulic power supply
before each use. Add fluid as necessary to fill the
lines.
• Flush pump before using it for the first time to
remove the light oil that was left in after factory test-
ing to protect pump from corrosion. Be sure solvent
used is compatible with the fluid to be pumped and
the pump’s wetted parts. See Technical Data, page
26. Flush until clean solvent comes out of hose.
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 dispensing and before
cleaning, checking, or servicing the equipment.
COMPONENT RUPTURE HAZARD
Overpressurizing any component can result in seri-
ous injury or property damage as a result of rupture,
fire, and/or explosion.The maximum working pres-
sure of each component in the system may not be
the same. To reduce the risk of overpressurizing any
component in the system:
• Be sure you know the maximum working pressure
of each component.
• Never exceed the maximum working pressure of
the lowest rated component in the system.
• Do not exceed the maximum input pressure.
• Use tubing, hoses and other components with
pressure ratings equal to or higher than the pump
rating.
• Do not exceed the maximum output pressure. The
pump has a rated ratio of 10:1. However, it is
capable of reaching stall pressures equal to 11.1
times the hydraulic input pressure. To calculate
the fluid output pressure, multiply the hydraulic
pressure shown on the hydraulic control module
gauge by 11.1.
For example:
900 psi hydraulic x 11.1 = 10,000 psi fluid output
6.2 MPa hydraulic x 11.1 = 69 MPa fluid
output
62.05 bar hydraulic x 11.1 = 689 bar fluid output
• Do not exceed the maximum pump cycle rate.
• Regulate hydraulic pressure to the pump so that
no fluid line component or accessory is overpres-
surized.

Operation
83A3005C
Starting Pump
1. Turn on hydraulic power supply.
2. Open return line shut-off valve (H) first, then slowly
open the hydraulic supply shut-off valve (L).
3. Adjust flow control valve (R) to limit the hydraulic
flow to no more than 3 gpm (11 lpm), which is
approximately 60 cycles per minute.
4. Adjust pressure reducing valve (N) to increase
hydraulic inlet pressure from 50 to 900 psi (0.34 to
6.2 MPa, 3.4 to 62.1 bar).
• Increasing inlet pressure, increases outlet pres-
sure.
• Decreasing inlet pressure, decreases outlet
pressure.
5. Open drain valve while priming pump.
6. When pump is primed, close drain valve.
Always use lowest pressure possible to obtain desired
results. This reduces pump wear.
If the Pump Leaks at the Fluid
Fittings
Tighten fittings (1, 5, 60) which are self-sealing and
have replaceable o-rings. If leaking persists, change
o-rings.
Shutdown
Relieve pressure, page 7, whenever you shutdown.
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:
• Never exceed 900 psi (6.2 MPa, 62.1 bar) Maxi-
mum Hydraulic input Pressure to the reciprocator.
• Never exceed 10,000 psi (69 MPa, 689 bar) Max-
imum Outlet Pressure from the displacement
pump.
• Accessories added to the pump fluid outlet side
should have at least a 10,000 psi (69 MPa, 689
bar) Maximum Working Pressure.
• Read and understand COMPONENT RUPTURE
HAZARD instructions, page 7.
FIG. 2
sealing
fitting (1, 5, 60)
reciprocator
o-ring
(1a, 5a,60a)
ti04478

Troubleshooting
3A3005C 9
Troubleshooting
Problem Cause Solution
Pump does not run. Closed dispense valve. Pump only runs with valve open.
Hydraulic supply pressure too low -
see gauge (M).
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, page 7. Check.
Clear obstructions.
Reciprocator damaged. Repair.
Pump speeds up or runs erratically. Pump piston and/or intake valve
worn.
Relieve pressure, page 7. Check
and repair.
Empty supply container. Refill and repair. 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, page 7. Check
and repair.
Pump runs but output low on both up
and down 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, page 7. Check.
Clear obstructions.
Excessive leakage of lubricant from
weep tube (B), page 4 or breather,
page 10.
Worn u-cup packing (44), (Parts
page 24)
Repair.
Excessive leakage of hydraulic fluid
from weepage tube (B), page 4 or
breather, page 10.
Worn V-block packing (16), (Parts
page 24)
Repair.
Hydraulic oil leaks from fittings in the
upper or lower reciprocator blocks
(31, 32) [Parts page 24].
Fittings 1, 5, 58, (Parts, page 24), are
loose, or their o-rings are worn or
damaged.
Tighten the self-sealing fittings. If
leaking persists, change o-rings.
Leak at output pressure relief hole
(FIG. 4, page 10).
Wrong style fitting. Install correct fitting.
Fitting is loose Tighten fitting.

Service
10 3A3005C
Service
NOTE: The reference letters used in the following Ser-
vice instructions refer to the Typical Installation illustra-
tion provided on page 4.
The reference numbers used in the following Service
instructions refer to the Parts pages beginning on page
22.
Pump Leaks at the Fluid Fittings
Tighten fittings (1, 5, 60; FIG. 3) which are self-sealing
and have replaceable o-rings. If leaking persists, change
o-rings.
Removing Displacement Pump
from Reciprocator
Disassembly
1. Flush pump.
2. Relieve pressure, page 7.
3. Clamp reciprocator/pump assembly in a brass-jaw
vise.
4. Disconnect fluid outlet hose (C) (Typical Installation,
page 4) from displacement pump.
5. Slowly loosen hydraulic supply fitting (60) and return
fitting (5) (FIG. 4). Remove hoses.
6. Install plugs in tube fittings and hose ends.
FIG. 3
Use of a hydraulic power supply with fluid tempera-
tures above 154°F (68°C) can create hot surfaces
which can burn if touched.
• Do not touch pump, motor, or if hydraulic system
fluid is above 154°F (68°C).
• Allow sufficient time for pump and motor to cool
before attempting any service or repair.
sealing
fitting (1, 5, 60)
reciprocator
o-ring
(1a, 5a,60a)
ti04478
FIG. 4
43
5
60
breather
pressure
relief hole

Service
3A3005C 11
7. Use a strap wrench on spacer tube (114) to unscrew
it out of the pump adapter (8) and slide it down as
far as it will go (FIG. 5).
8. Pull connecting rod (107) out of spacer tube (114) to
access the pin (204). Remove pin (204) (FIG. 5).
9. Unscrew displacement rod (35) from connecting rod
(107) from displacement rod (35) (FIG. 5).
Replacing Throat Seals
NOTE: Replace throat seals if fluid leaks excessively
through the weep tube (B), page 4. This procedure can
be done without disassembling entire reciprocator.
Disassembly
1. Relieve pressure, page 7.
2. Disconnect reciprocator from displacement pump
(see Removing Displacement Pump from Recipro-
cator, page 10).
3. Remove eight capscrews (15) and washers (27)
from bottom of pump adapter (8). Tap pump adapter
to loosen it and pull it off the motor housing (43)
(FIG. 6).
FIG. 5
114
35
204
35
107
8
107
FIG. 6
15
27
8
43

Service
12 3A3005C
4. Remove retainer nut (11) and seal (44) from top of
pump adapter (8).
5. Remove four capscrews (46) and washers (52) from
bottom of motor housing (43) and remove motor
housing from bottom cylinder cap (32).
6. Loosen nut (45a) on both ends of fluid tube (45)
(FIG. 9).
7. Use a wrench to loosen elbow (1) and tee (60).
Remove fluid tube (45). Install plug in each fitting to
prevent contamination (FIG. 10).
FIG. 7
FIG. 8
11
44
8
46
43
32
16
52
FIG. 9
FIG. 10
45a
45a
45
60
1
45

Service
3A3005C 13
8. Check o-rings (1a and 60a) on fittings (1 and 60)
and replace them if they are worn or damaged.
9. Remove capscrew (3), nut (36) and lockwashers
(37). Remove the reciprocator cap plate (30).
10. Gently tap on bottom cylinder cap (32) to loosen cyl-
inder cap from cylinder (25) using a rubber or plastic
mallet.
NOTE: It is not necessary to remove the tie rods (38)
from the bottom cylinder cap (32).
11. Remove seal (16) from bottom of cylinder cap (32).
Reassembly
Use Kit 247455. Use all new parts included in the kit.
1. Install seal (16) in bottom of cylinder cap (32) in the
orientation shown in FIG. 13.
2. Reassemble cylinder cap (32) to motor housing
(43). Install lock washers (52) and cap screws (46)
(FIG. 13). Torque the capscrews to 28-32 ft-lb (38 to
43 N.m).
NOTE: When attaching the motor housing (43) onto the
bottom cylinder cap (32), be sure that the adapter (72) in
the motor housing and the port (32b) in the bottom cylin-
der cap are facing opposite directions as shown in FIG.
14.
FIG. 11
FIG. 12
60a
1a
60
1
30
3
39
2
36
37
FIG. 13
FIG. 14
16
32
32b 32
72
43

Service
14 3A3005C
3. Install seal (44) on retainer nut (11). Install retainer
nut in pump adapter (8) (FIG. 14). Torque retainer
nut to 54 to 56 ft-lbs (73-75 N.m).
4. Slide bottom cylinder cap (32) onto the cylinder (25)
ensuring the tie rods (38) go through their respec-
tive holes in the top cylinder cap (31).
NOTE: When attaching the bottom cylinder cap (32)
onto the cylinder (25) be sure that the port (31b) in the
top cylinder cap (31) and the port (32b) in the bottom
cylinder cap (32) are in line with each other. Be sure
o-rings (13) are in place in the top and bottom cylinder
caps as shown in FIG. 15.
5. Install lock washers (37) and nuts (36) onto tie rods
(38). Torque nuts to 28-32 ft-lbs (38-43 N.m) (FIG.
16).
6. Install pump adapter (8) to motor housing (43).
Install the lockwashers (27) and capscrews (15).
Torque capscrews to 170-180 in.-lbs (19-20 N.m).
7. Reinstall fluid tube (45) and fittings (1). Torque fit-
tings to 28 to 32 ft-lb (38 to 43 N.m.)
8. Install displacement pump, see Displacement Pump
and Reciprocator Reassembly instructions, page
20.
FIG. 15
31
31b
13
25
32
32b
13
FIG. 16
37
36
38

Reciprocator Repair
3A3005C 15
Reciprocator Repair
• Clean and inspect all parts for wear or damage.
Replace worn parts as needed. For best results,
always replace all the o-rings and seals when you
disassemble the pump. Repair Kit 247455 is avail-
able. Parts included in the kit are marked with an
asterisk, for example (23*), in the text and drawings.
Always replace seals (23* and 24*) and seals (16*
and 44*) together.
•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 I are required.
Be sure their shelf life is within the manufacturer’s
recommendations.
• For Step 8, page 17; use Loctite®609 on yoke (9)
and rod (12). On all other threaded surfaces, use
Loctite®242 or Perma-Loc®115 as required.
Disassembly
1. Relieve pressure, page 7.
2. Drain oil out of reciprocator.
3. Disconnect reciprocator from displacement pump
(see Removing Displacement Pump from Recipro-
cator, page 10). Place reciprocator in a drain pan.
4. Remove eight capscrews (15) and washers (27)
from bottom of pump adapter (8). Tap pump adapter
to loosen it and pull it off the motor housing (43)
(FIG. 6).
FIG. 17
15
27
8
43

Reciprocator Repair
16 3A3005C
5. Place bottom cap (32) in vise. Remove four cap-
screws (46) and lockwashers (52).
6. Pull adapter (43) off bottom cap (32). Inspect seals.
If needed, replace seals. See Replacing Throat Seal
Disassembly instructions on page 11.
7. Remove capscrew (3), nuts (36) and lockwashers
(37) on top of reciprocator.
8. Remove cap plate (30) (FIG. 19).
9. Use a rubber or plastic head mallet to tap the bot-
tom of the displacement rod (35) and loosen cylin-
der (25).
10. Grasp top of cylinder cap (31) and pull the displace-
ment rod (35) out of the cylinder (25). Lay assembly
on its side.
NOTE: It is not necessary to remove tie rods (38) from
the bottom cylinder cap (32).
11. Place a clean rag around yoke (9) to prevent losing
detent balls (7) and spring (6) installed in the valve
stop (26). Lightly push down the valve stop with your
thumbs while gripping yoke to disengage yoke from
valve stop and valve sleeve (29).
12. Secure hex end of displacement rod (34) in a vise.
Use a spanner wrench (sw) in pin holes of the piston
(22) to remove piston from the displacement rod.
FIG. 18
FIG. 19
46
43
32
16
52
3
36
37
30
FIG. 20
FIG. 21
26
9
29
rag
34
22
sw

Reciprocator Repair
3A3005C 17
13. Visually inspect the spring (21). If there is wear or
damage, remove nut (18), spring (21) and retainers
(20) from the trip rod (12) (FIG. 22).
Reassembly
NOTE:
• Use a surface cleaner such as chlorinated sol-
vent on the threads of all parts that are being
reused for reassembly. Blow part with com-
pressed air.
• Use a 1/4-28 UNF-2A tap to remove adhesive
from internal threads of yoke (9).
• Thread sealer and primer are required. See
Reciprocator Repair Notes, page 15 for specifi-
cation.
•Loctite
®609 is used only in Step 3 of this proce-
dure.
1. If needed, install a new spring over trip rod as fol-
lows (FIG. 23):
• one retainer (20),
•newspring(21),
• second retainer (20).
2. Thread nut (18) onto rod until it runs out of thread so
that it bottoms out on the rod’s shoulder (FIG. 23).
3. If valve yoke (9) was removed from trip rod (12)
during the disassembly procedure, apply Loctite®
609 thread sealant to first two or three internal
threads of yolk (9).
4. Apply Primer to external threads of trip rod (12).
Allow Primer 3-4 minutes to dry. Install trip rod to
yoke (9). Torque to 54-56 in.-lbs (6.1 to 6.3 N.m).
Remove excess sealant.
5. Apply Loctite®242 or Perma-Loc 115 thread sealant
to first two to three threads of valve assembly (31).
6. If capscrews (51) were removed during the disas-
sembly procedure, apply thread sealant to the first
two or three internal threads of valve stop (26) (FIG.
24, page 18).
7. Apply Primer to external threads of valve sleeve
(29). Allow Primer 3-4 minutes to dry. Install cap
screws (51). Torque to 42-45 in.-lbs (4 to 5 N.m).
Remove excess sealant.
8. Remove o-ring (13) from bottom of cylinder cap (31)
and replace it with a new o-ring.
FIG. 22
18
20
21
20
12
FIG. 23
NOTICE
In order to ensure a tight and secure seal, allow 24
hours for sealant applied in Steps 3 and 5 to cure
before operating reciprocator.
18
20
21
20

Reciprocator Repair
18 3A3005C
9. Use a spanner wrench to screw piston (22) onto
displacement rod (34). Torque to 40 to 48 ft-lb (54 to
65 N.m).
10. Lay Assemblies A and B (FIG. 24) on work bench.
11. Slide Assembly B in into center of tool (D), Part No.
189305. Align upper detent holes (C) of yoke (9)
with center line of tool (D) (FIG. 24).
12. Insert spring (6) and one ball (7) into valve stop (26)
of Assembly A. Tilt valve stop and start guiding it
into tool (D), making sure ball is sliding into rounded
slot in tool (D). Place other ball at the other end of
spring and push it in with your thumb while rotating
valve stop (26) until spring is horizontal and balls
are in place. Continue holding this assembly
together (FIG. 24).
13. Slide valve stop assembly down into tool. Make sure
balls (7) snap into upper set of holes (C) in yoke (9)
and curved ends of guide clamp have engaged
valve sleeve (29) groove. Slide tool (D) back over
rod (12) to remove it (FIG. 24).
14. Place adapter (43) in a vise. Install seals as
described in Replacing Throat Seal Reassembly
instructions, page 13.
15. Reassemble cylinder cap (32) to motor housing
(43). Install lock washers (52) and cap screws (46)
(FIG. 13). Torque the capscrews to 28-32 ft-lb (38 to
43 N.m).
NOTE: When attaching the motor housing (43) onto the
bottom cylinder cap (32), be sure that the adapter (72) in
the motor housing and the port (32b) in the bottom cylin-
der cap are facing opposite directions as shown in FIG.
25.
16. Attach adapter (8) to motor housing (43) using eight
capscrews (15) and lock washers (27). Torque
capscrews to 25-30 ft-lbs (34-41 N.m).
FIG. 24
9
ti10606a
12
D
C
7
6
Assembly A
Assembly B
31 26
51
29
FIG. 25
FIG. 26
32b 32
72
43
8
43
27
15

Reciprocator Repair
3A3005C 19
17. If tie rods (38) were removed, reinstall them with
short threaded end up. The other end should be
screwed about 9/16” into bottom cylinder cap (32).
When reinstalling cylinder (25), be sure port in top cylin-
der cap (31) and port in the bottom cylinder cap (32) are
in line with each other. Be sure o-rings (13) are in place
in the top and bottom and cylinder caps (31 and 32).
18. Place cylinder (25) on cylinder cap (32).
19. Install o-ring (49) in deep, lower groove of piston
(22). Install seal (23) over o-ring. Install piston bear-
ing (24) around upper groove of piston. Holding pis-
ton bearing in place to avoid damage, slide cylinder
over piston and press it down.
20. Install cap plate (30).
21. Install capscrew (3), o-ring (39) and washer (2).
Install lockwashers (37) and nuts (36). Torque nuts
to 28 to 32 ft-lb (38 to 43 N.m).
22. Reinstall fluid tube (45) and fittings (1). Torque fit-
tings to 28 to 32 ft-lb (38 to 43 N.m).
NOTE: Make sure the displacement rod (35) on the
assembled reciprocator is exposed so the pump can be
connected to it.
Displacement Pump Repair
Disassembly
• Be sure you have all necessary parts on hand
before you start. If using a repair kit, use all parts in
the kit for the best results.
• Displacement Pump Repair Kit 241623 is available.
Parts included in the kit are marked with a dagger
(†) symbol in the parts drawing and list, page 26.
1. If possible, flush pump.
2. Relieve pressure, page 7.
3. Follow instructions for Removing Displacement
Pump from Reciprocator, page 10.
4. Clamp pump in vise.
5. Use wrench to screw shovel tube (117) off pump
cylinder (109).
6. Use a wrench to screw piston shovel (116) off of
shovel rod (108).
7. Use strap wrench on pump cylinder (109) to screw it
out of extension tube (114).
8. Use a 7/8 inch crow foot connector wrench to screw
retainer seal (113) out of pump cylinder (109).
Remove bearing (111) and seal (112).
9. Screw the shovel rod (108) out of the piston (102).
Remove lower ball (106).
10. Screw piston (102) out of extension rod (107).
Remove upper ball (106†), retaining washer (103)
and seal (104).
NOTICE
To avoid damaging shovel tube, do not use slots in
tube to tighten or loosen tube.

Reciprocator Repair
20 3A3005C
Reassembly
1. Clean all the parts in a compatible solvent and
inspect them for wear or damage. Use all parts in
the repair kit, replace other parts as necessary.
2. Generously lubricate all parts with light, water-resis-
tant grease.
3. Install upper ball (106), retaining washer (103) and
seal (104), with lips facing up, in extension rod
(107). Screw piston (102) into extension rod (107).
Torque the piston to the extension rod to 25-30 ft-lb
(34-41 N.m).
4. Install lower ball (106) into end of shovel rod (108).
Screw the shovel rod (108) to piston (102). torque
the shovel rod to the piston to 25-30 ft-lb (34-41
N.m).
5. Install bearing (111) and seal (112) with lips facing
up, in pump cylinder (109). Screw retainer seal
(113) into pump cylinder (109).
6. Screw together pump cylinder (109) and extension
tube (114). Use a 7/8 inch crow foot wrench on
retainer seal (113). torque to 45-55 ft-lb (61-75 N.m)
(FIG. 27).
7. Use a wrench to screw together piston shovel (116)
and shovel rod (108). Torque to 145-155 in.-lb
(16.4-17.5 N.m).
Reassembling Displacement
Pump to Reciprocator
1. Clamp reciprocator in vise.
2. Replace nylon pellet (207) in threads on bottom of
pump adapter (8) (FIG. 28).
3. Install new gasket (202) in pump adapter (8) (FIG.
28).
FIG. 27
113 109
FIG. 28
207
8
202