Graco Series A Parts list manual

308302U
EN
Instructions/Parts
12:1 Ratio Stainless Steel
DynaMite™190 Extruders
Used for precision dispense of single component viscous materials for 1 quart (.95 liter)
and 1 gallon (3.79 liter) containers. For professional use only.
Not approved for use in European explosive atmosphere locations.
Part No. 25D097, Series A
Part No. 235871, Series D
Includes Pump and Ram
1200 psi (8.3 MPa, 83 bar) Maximum Fluid Working Pressure
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
Important Safety Instructions
Read all warnings and instructions in this manual
and in all related manuals. Save all instructions.
25D097, Series A 235871, Series D

Related Manuals
2308302U
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Identification . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pump Location and Set Up . . . . . . . . . . . . . . . . . 7
Connect and Disconnect Tubes . . . . . . . . . . . . . 8
Pump Components and Accessories . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 9
Flush the System . . . . . . . . . . . . . . . . . . . . . . . 10
Start and Adjust the Ram . . . . . . . . . . . . . . . . . 10
Start and Adjust the Pump . . . . . . . . . . . . . . . . 11
Prime the Pump and Pump Fluid . . . . . . . . . . . 12
Change the Fluid Can . . . . . . . . . . . . . . . . . . . . 12
Shutdown and Care of the Pump . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
235871, Series D Parts - Standard Duty . . . . . . . 17
25D097, Series A Parts - Heavy Duty . . . . . . . . . . 20
235870, Series D Parts - Standard Duty . . . . . . . 22
25C829, Series A Parts - Heavy Duty . . . . . . . . . . 24
Accessory Can Opener
(not supplied with unit) . . . . . . . . . . . . . . . . . 26
Wiper Plate Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
235871 - Standard Duty . . . . . . . . . . . . . . . . . . 28
25D097 - Heavy Duty . . . . . . . . . . . . . . . . . . . . 29
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Data - Fluid Flow Chart (235871) . . . 31
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 32
Related Manuals
Manuals
Part Description
3A3442 NXT Air Motor Repair and Parts Manual
3A5311 Tandem Heavy Duty DynaMite™Supply Sys-
tem Instructions - Parts Manual

Part Numbers
308302U 3
Part Numbers
* Wiper plates must be ordered separately.
Part No. Maximum Fluid Working Pressure Description
235871 1200 psi (8.3 MPa, 83 bar) DynaMite 190 Extruder Assembly, Series D - Approved
25D097 1200 psi (8.3 MPa, 83 bar)
Heavy Duty DynaMite 190 Extruder Assembly, Series D -
Approved
235870 1200 psi (8.3 MPa, 83 bar) DynaMite Pump Assembly, Series D
25C829 1200 psi (8.3 MPa, 83 bar) Heavy Duty Pump Assembly - Series A
224908* Wiper Plate, Series A, 1 gallon (3.79 liter) size
224923* Wiper Plate, Series B, 1 quart (.95 liter) size
25C843* Heavy Duty Wiper Plate, Series A, 1 gallon (3.79 liter) size

Warnings
4308302U
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.
SKIN INJECTION HAZARD
High-pressure fluid from spray gun, 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 the 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.
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.

Warnings
308302U 5
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or sol-
vent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Use only grounded hoses.
• Hold dispensing device/gun firmly to side of grounded pail when triggering into pail. Do not use pail
liners unless they are anti-static or conductive.
•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.
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.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request Safety Data Sheet (SDS) 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.
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. 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.

Component Identification
6308302U
Component Identification
Key:
P Wiper Plate Assembly
1Pump
8 Bleed-Type Mater Air Valve
18 Air Assist Valve (Push Button
24 Clamps
25 Pump Bleeder Valve
27 (A) Pump Air Regulator
27 (B) Ram Air Regulator
28 Fluid Outlet Fitting
30 (A) Pump Air Pressure Gauge
30 (B) Ram Air Pressure Gauge
33 Pump Bracket
34 Base
36 Ram Director Valve
37 Air Assist Valve Connector
39 Clamp Wing Screws
57 Air Inlet for Main Air Line
76 Air Tube to Wiper Plate
111 Pump Fluid Intake Housing
302 Wiper Plate Capscrews
303 Wiper Bleed Valve
305 Wiper Plate Ring
310 Wiper Plate Connector
FIG. 1: System Components
28
1
302
25
P
8
27(B)
27(A)
18
37
57
76
111
310
36
24
39
303
305
30(B)
30(A)
34
33

Installation
308302U 7
Installation
Grounding
Pump: unscrew the green grounding screw (W) and
washer (X) located on the ram base (Z). Install a 1.5
mm2(12 awg) minimum ground wire (Y) and secure with
the screw and washer. Connect the other end of the
ground wire to a true earth ground.
Air and fluid hoses: use only electrically conductive
hoses with a maximum of 500 ft. (150 m) combined
hose length to ensure grounding continuity. Check elec-
trical resistance of hoses. If total resistance to ground
exceeds 29 megohms, replace hose immediately.
Air compressor: follow manufacturer’s recommenda-
tions.
Spray gun / Dispense valve: ground through connec-
tion to a properly grounded fluid hose and pump.
Fluid supply container: follow local code.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray
gun/dispense valve firmly to the side of a grounded
metal pail, then trigger the gun/valve.
Pump Location and Set Up
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in FIG. 1 on page 6 and
the parts drawings. Refer to those for installation.
If you supply your own accessories, be sure they are
adequately sized and pressure-rated to meet the sys-
tem’s requirements. Contact your Graco distributor for
assistance in designing a system to suit your needs.
1. Place the unit on a hard, level surface. Check that
the unit is level in all directions. Refer to Dimen-
sions on page 28 to ensure that there is sufficient
overhead clearance for the pump when the ram is
fully raised. Leave room on both sides so the air
regulators will be easily accessible.
2. Read the section Pump Components and Acces-
sories on page 8. Connect an air supply hose to the
1/4 npt(f) main air inlet fitting (57). See FIG. 1 on
page 6. Refer to Connect and Disconnect Tubes
on page 8.
Wiper Plate Setup
1. Unpack the wiper plate (P). Back out the screws
(302) so they clear the pump fluid intake housing
(111).
2. Raise the ram by setting the ram director valve
switch (36) to the up position and increasing the set-
ting of the ram air regulator (27B).
3. Place the wiper plate (P) on a 2 in. thick x 4 in. wide
block of wood. Center the wiper plate and the wood
block on the base, under the pump intake housing
(111).
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. 2: Grounding Connection on Pump
Z
Y
W
X
To reduce the risk of serious injury and damage to
equipment, do not shut off the air supply to the ram
when the ram is raised. Doing so will cause the pump
to fall uncontrolled to the bottom.

Installation
8308302U
4. Set the ram air regulator (27B) to zero. Set the ram
director valve switch (36) to the down position. As
the ram unit slowly falls, guide the pump intake
housing (111) into the wiper plate (P).
5. Set the ram air regulator (27B) to 10 psi (0.07 MPa,
0.7 bar). Push down on the pump to install the wiper
plate (P) onto the intake housing (111). Secure the
wiper plate to the pump with the two screws (302).
6. Connect the 660 mm (26 in.) air line tube (76) from
the connector (37) at the air assist valve (18) to the
connector (310) at the wiper plate (P). Refer to Con-
nect and Disconnect Tubes on this page.
Connect and Disconnect Tubes
Follow these steps when connecting and disconnecting
any air tubes on the DynaMite 190 Extruder assembly
Connection
1. Grasp the tube, then slowly push it straight into the
fitting until it stops.
2. Be sure that the tube is securely connected, and will
not pull out when air pressure is applied. To check,
pull gently on the tube.
Disconnection
1. Follow the Pressure Relief Procedure on page 9.
2. Push evenly on the fitting’s red release button.
3. While holding the release button in, pull the tube out
of the fitting.
4. To reuse the tubing, cut off the previous connection
portion at 90°, being careful not to damage the outer
diameter of the tube.
NOTE: Use of a tube cutter is recommended. The fitting
will leak if the tubing is not cut at 90°.
Pump Components and
Accessories
The following components are supplied with the pump
(see FIG. 1 on page 6).
•The bleed-type master air valve (8) is supplied
with your system to relieve air trapped between this
valve and the pump after the air is shut off. Trapped
air can cause the pump to cycle unexpectedly. The
valve is located close to the pump, downstream
from the pump air regulator.
•The pump air regulator (27A) controls pump
speed and outlet pressure by adjusting the air pres-
sure to the pump. The regulator is located upstream
from the bleed-type master air valve.
•The ram air regulator (27B) controls ram speed by
adjusting the air pressure to the ram, and also con-
trols the pressure exerted by the wiper plate on the
fluid.
•The pump bleeder valve (25) is supplied in your
system to relieve fluid pressure in the displacement
pump, hose, and dispensing valve. Triggering the
dispensing valve to relieve pressure may not be suf-
ficient. Be sure the drain hole in the valve is pointing
down. This valve is also used to bleed air from the
pump when priming.
Air Line
Connect an air supply line to the 1/4 npt(f) main air inlet
fitting (57). Install an air line filter and lubricator in the
main air line. In the main air line, upstream from all other
air line accessories, install a second bleed-type master
air valve to shut off all air to the system and to isolate
the accessories for servicing.
Fluid Line
Connect a fluid line to the fluid outlet fitting (28). Con-
nect a suitable dispensing valve to the free end of the
line.
To help reduce the risk of serious injury when adjust-
ing or repairing the pump, including skin injection,
splashing fluid, and moving parts, the pump includes
two required safety devices: the bleed-type master air
valve (8) and the pump bleeder valve (25).

Operation
308302U 9
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Lock the sprayer, dispenser, or gun/valve trigger of
the equipment that is being used with this extruder.
2. Disconnect the main air line from the machine.
3. Set the ram director valve to the down position. The
ram slowly drops.
4. Quickly move the ram director valve up and down to
bleed air from the ram cylinder.
5. Unlock the dispensing device trigger.
6. Hold a metal part of the gun/valve firmly to the side
of a grounded pail and trigger the dispensing device
to relieve pressure.
7. Lock the dispensing device trigger.
8. Open the pump bleeder valve.
9. Leave the pump bleeder valve open until you are
ready to dispense again.
If you suspect that the spray tip/nozzle or hose is com-
pletely clogged, or that pressure has not been fully
relieved, proceed as follows:
10. Very slowly open the pump bleeder valve, having a
container ready to catch the drainage.
11. Very slowly loosen the hose end coupling to relieve
pressure gradually; then loosen it completely.
12. Clear the tip/nozzle or 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.
FIG. 3: Pressure Relief Components
Ram Director Valve
Main Air Line
Pressure Gauge
FIG. 4: Open Valves
Pump Bleeder Valve

Operation
10 308302U
Flush the System
NOTE: The pump is tested with lightweight oil, which is
left in to protect the pump parts. If the fluid you are using
might be contaminated by the oil, flush it out with a com-
patible solvent before using the pump.
Flush with a fluid that is compatible with the fluid you are
pumping and with the wetted parts in your system.
Check with your fluid manufacturer or supplier for rec-
ommended fluids and flushing frequency. Always flush
the pump before fluid dries on the displacement rod.
1. Follow the Pressure Relief Procedure on page 9.
2. Remove the tip/nozzle from the dispensing device
you are using with the pump.
3. Hold a metal part of the dispensing device firmly to
the side of a grounded metal pail.
4. Start the pump. See Start and Adjust the Pump on
page 11. Always use the lowest possible fluid pres-
sure when flushing.
5. Trigger the dispensing device.
6. Flush the system until clear solvent flows from the
dispenser.
7. Relieve the pressure. See page 9.
Start and Adjust the Ram
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in FIG. 1 on page 6 and
the parts drawings. Refer to those for operation.
1. Close all air regulators and bleed-type air valves.
2. Open the air valve in the main air line and set the
ram air regulator (27B) to 28 psi (200 kPa, 2 bar).
Set the ram director valve switch (36) to the up posi-
tion and let the ram rise to its full height. To change
the speed at which the ram raises and lowers,
adjust the air regulator to increase or decrease the
air volume.
3. Check that the fluid can is not dented or out of
shape, which will damage the wiper plate and cause
leakage around the wiper. Cut off the top of the fluid
can with the can opener, or remove the bottom of
the can. Be sure that the edge is free of burrs, which
will damage the wiper plate. If necessary, bend the
edge back with pliers so the wiper plate will enter
the can easily. Lubricate the wiper ring (305) to help
the plate enter the can easily.
4. Set a can of fluid on the ram base, centering it under
the wiper plate (P).
To avoid fire and explosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest pos-
sible pressure.
NOTICE
Never leave water or water-based fluid in a carbon
steel pump overnight. If you are pumping
water-based fluid, flush with water first, then with a
rust inhibitor, such as mineral spirits. Relieve pres-
sure, but leave rust inhibitor in the pump to protect
parts from corrosion.
To reduce the risk of serious injury and damage to
equipment, do not shut off the air supply to the ram
when the ram is raised. Doing so will cause the pump
to fall uncontrolled to the bottom. Also, as the ram is
raised and lowered, the wiper plate, ram tubes, and
pump mounting bracket move. To reduce the risk of
pinching or amputation of fingers, keep your hands
away from the wiper plate, lip of the fluid can, pump
bracket, ram tubes, and air motor coupling cavity while
the pump is operating.
If the can has a welded seam, position it with the seam
facing the rear of the pump to avoid injury due to splat-
tering fluid if the can leaks at the seam.

Operation
308302U 11
5. Loosen the wiper plate bleed valve (303) enough to
allow air trapped under the wiper plate to escape.
With your hands away from the lip of the can and
the wiper plate, set the ram director valve switch
(36) to the down position and lower the ram until the
wiper plate enter the can. Reduce the air pressure
when the plate enters the can.
NOTE: If the wiper plate does not enter the can easily,
increase the ram pressure; once it enters the can,
immediately reduce the pressure.
6. Continue to lower the ram until fluid appears at the
wiper plate vent hole. Tighten the wiper plate bleed
valve (303) securely. See FIG. 1 on page 6.
7. Clamp the can in place with the clamps (24) and
wing screws (39), being sure the clamp catches the
lip of the can.
Start and Adjust the Pump
1. Supply fluid to the pump per the requirements of
your system. See Prime the Pump and Pump
Fluid on page 12.
2. Close the pump air regulator (27A).
3. Set the ram air regulator (27B) to 50 psi (3.5 bar).
4. Set the ram director valve (36) to the down position.
5. Reduce the air motor regulator pressure to zero and
open the air motor valve.
6. Adjust the air motor regulator until the pump starts.
7. Cycle the pump slowly until all air is pushed out and
the pump and hoses are fully primed.
8. Release the dispensing device trigger and lock the
safety. The pump should stall against the pressure.
9. If the pump fails to prime properly, open the pump
bleeder valve slightly. Use the bleed hole on the
underside of the valve as a priming valve until the
fluid appears at the hole. Then close the plug.
The air motor piston and fluid piston (located inside the
air motor cylinder and coupling) move when air is sup-
plied to the motor. Do not place your hand or fingers
into the air motor coupling cavity while the pump is
operating.
Also, keep hands and fingers away from the priming
piston (see FIG. 9 on page 19) during operation and
whenever the pump is charged with air. During opera-
tion, the priming piston extends beyond the intake
housing to pull material into the pump and can ampu-
tate a hand or finger caught between it and the intake
housing. Follow the Pressure Relief Procedure on
page 9 before checking, clearing, or cleaning the prim-
ing piston.
FIG. 5: Set Ram Director Valve for Startup
To reduce the risk of skin injection, do not use your
hand or fingers to cover the bleed hole on the under-
side of the bleeder valve when priming the pump. Use
the handle or a crescent wrench to open and close
the bleeder plug. Keep your hands away from the
bleed hole.
Ram Director Valve
Pressure Gauge
Ram Air Regulator

Operation
12 308302U
NOTE: Always use the lowest possible fluid pressure to
bleed air out of the pump.
NOTE: When changing fluid containers with the hose
and dispensing device already primed, open the pump
bleeder valve to help prime the pump and vent air
before it enters the hose. Close the valve when all air is
eliminated.
10. With the pump and lines primed, and with adequate
air pressure and volume supplied, the pump starts
and stops as you open and close the dispensing
device. In a circulating system, the pump speeds up
or slows down on demand until the air supply is shut
off.
11. Use the air motor regulator to control the pump
speed and the fluid pressure.
Prime the Pump and Pump Fluid
1. Be sure the pump air regulator (27A) is closed.
Then set the ram air regulator (27B) to be about 22
psi (150 kPa, 1.5 bar). Set the ram director valve
switch (36) to the down pump.
2. Open the bleed-type master air valve (8). Set the
pump air regulator (27A) to 28 psi (200 kPa, 2 bar).
3. Open the pump bleeder valve (25) to allow air to
bleed from the pump. When the pump is fully
primed, close the valve.
4. Keep the director valve switch (36) in the down posi-
tion while the pump is operating.
NOTE: Adjust the air pressure to the ram as needed,
but do not increase it to a level where fluid is forced past
the wiper plate.
Change the Fluid Can
1. Stop the pump.
2. Close the bleed-type master air valve (8), but leave
air pressure on to the ram.
3. Set the ram air regulator (27B) to below 30 psi (210
kPa, 2.1 bar).
4. Open the dispensing valve and relieve all fluid pres-
sure in the system. See the Pressure Relief Proce-
dure on page 10.
5. Set the ram director valve switch (36) to up.
6. Push in the air assist valve (18) and hold it in until
the wiper plate clears the top of the can.
FIG. 6: Pump Bleeder Valve
NOTICE
Do not allow the pump to run dry. It will quickly accel-
erate to a high speed, causing damage. If your pump
is running too fast, stop it immediately and check the
fluid supply. If the container is empty and air has
been pumped into the lines, refill the container and
prime the pump and the lines, or flush and leave it
filled with a compatible solvent. Eliminate all air from
the fluid system.
NOTICE
Always use the lowest air pressure necessary to get
the desired results. Higher pressures cause prema-
ture tip/nozzle and pump wear.
Pump Bleeder Valve
Bleed Hole
NOTICE
If the fluid has set up and the wiper plate (P) is stuck
in the can, do not increase the setting of the ram air
regulator (27B) to remove the plate. Excessive pres-
sure in the can may cause the can to rupture. If you
cannot pull the can off the plate by hand, loosen the
two screws (302) holding the plate to the pump (1),
disconnect the air tube (76) from the plate, and
remove the can and plate. It may be necessary to cut
the can to remove the plate.

Operation
308302U 13
7. Loosen the clamps (24) and remove the empty can.
Set the full can on the ram base and position it
under the wiper plate.
8. Lower the ram and adjust the position of the can rel-
ative to the wiper plate. See Start and Adjust the
Ram on page 10.
9. Clamp the can in place.
Shutdown and Care of the Pump
1. Stop the pump at the bottom of the stroke to prevent
fluid from drying on the exposed displacement rod
and damaging the throat packings.
2. Set the ram director valve to the down position.
3. Follow the Pressure Relief Procedure on page 9.
4. Always flush the pump before the fluid dries on the
displacement rod.
If the can has a welded seam, position it with the seam
facing the rear of the pump to avoid injury due to splat-
tering fluid if the can leaks at the seam.
NOTICE
Never leave water or water-based fluid in a carbon
steel pump overnight. If you are pumping
water-based fluid, flush with water first, then with a
rust inhibitor, such as mineral spirits. Relieve pres-
sure, but leave rust inhibitor in the pump to protect
parts from corrosion.
FIG. 7: Ram Director Valve Position for Shutdown.
Ram Director Valve

Troubleshooting
14 308302U
Troubleshooting
Before servicing this equipment always make sure to
follow the Pressure Relief Procedure on page 9.
Check all possible problems and solutions before disas-
sembling the pump.
* To determine if the fluid hose or gun is obstructed, relieve the pressure. Disconnect the fluid hose and place a
container at the pump fluid outlet to catch any fluid. Turn on the air just enough to start the pump (about 20-40 psi
[140–280 kPa, 1.4–2.8 bar]). If the pump starts when the air is turned on, the obstruction is in the fluid hose or dis-
pensing device.
Problem Cause Solution
Pump fails to operate. Restricted line or inadequate air
supply; closed or clogged valves.
Clear; increase air supply. Ensure
that all valves are open.
Obstructed fluid hose or gun/valve;
fluid hose ID is too small.
Open, clear*; use a hose with a
larger ID.
Fluid dried on displacement rod. Clean. Always stop pump at the bot-
tom of the stroke. Keep enclosed
wet cup 1/3 filled with a compatible
solvent.
Dirty, worn, or damaged motor
parts.
Clean or repair; see separate motor
manual.
Pump operates, but output is low. Fluid is too heavy for pump priming Use drain/purge valve. use a ram.
Held open or worn intake valve or
seals.
Clear valve. Replace seals.
Erratic or accelerated pump. Exhausted fluid supply. Refill and prime.
Fluid is too heavy for pump priming. Use drain/purge valve.
Held open or worn intake valve of
seals.
Clear valve. Replace seals.
Held open or worn priming piston. Clear; service.
Worn packings in displacement
pump.
Replace packings.

Service
308302U 15
Service
Disassembly
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in FIG. 8 on page 17 and
the parts drawings. Refer to those for service.
NOTE: Repair Kit 223894 is available to repair 235871,
and Repair Kit 25C844 is available to repair 25D097.
Parts included in these kits are marked with a † symbol
in the parts list on page 23 and page 25. For the best
results, use all the new parts in the kit.
1. Follow the Pressure Relief Procedure on page
10.
2. Disconnect all hoses. Remove the wiper plate.
Remove the fluid outlet elbow (28), noting its posi-
tion relative to the air inlet. Remove only the three
screws (38) and lock washers (41) holding the pump
to the mounting bracket (33).
3. Rotate the pump so the bleeder valve (25) is aligned
with the slot in the mounting bracket (33), and lift the
pump straight up through the bracket.
4. Remove the pin (144) from the fluid piston (106).
Unscrew the air motor shaft from the fluid piston by
turning the screw (145).
5. Unscrew the adapter (214) from the cylinder cou-
pling (196). Pull the air motor coupling straight up
until it clears the fluid piston (106).
6. Hold the fluid piston (106) steady by inserting a
small screwdriver or punch into the 4 mm diameter
hole (A). Remove the screw (145) and lock washer
(135) holding the priming piston (115) to the priming
piston rod (110).
7. Pull the priming piston rod (110) and fluid piston
(106) straight up out of the fluid housing (109).
Remove the pin (123), and unscrew the priming pis-
ton rod from the fluid piston.
8. Unscrew the intake valve housing (111) from the
fluid housing (109). Remove the o-ring (161) from
the intake valve housing.
9. Remove the intake valve (114) and valve stop (112)
from the intake valve housing (111).
10. Unscrew the wet-cup/packing nut (107). Remove
the u-cup packing (163) from the throat. Remove
the o-ring (162) from the wet-cup/packing nut.
11. 13. Clean all parts with a solvent compatible with
the fluid you are pumping, and inspect for wear or
damage. Reassemble as explained on this page.
Reassembly
NOTE: Lubricate all packings and o-rings with a com-
patible grease before reassembling.
1. Install the u-cup packing (163) in the throat of the
fluid housing (109), with the lips facing down. install
the o-ring (162) into the groove above the bearing of
the wet-cup/packing nut (107). Apply thread lubri-
cant and install the wet-cup/packing nut in the fluid
housing (109). Torque to 298-314 in-lb (35–37
N•m).
2. Screw the priming piston rod (110) into the fluid pis-
ton (106) until the holes align. Install the pin (123) in
the holes. Carefully slide the assembled piston and
rod down through the wet-cup and fluid housing.
3. Place the intake valve (114) onto the seat of the
intake valve housing (111). Insert the valve stop
(112) into the intake valve housing, with the flat side
facing up. Be sure the valve stop (112) seats on the
lip of the intake housing. Lubricate the o-ring (161).
Bend it into a kidney shape, then carefully push it
into the inner groove of the intake valve housing
(111), to avoid damaging it.
4. Apply thread lubricant to the lower threads of the
fluid housing (109). Bring the fluid housing and
intake valve housing (111) together, making sure
the priming piston rod (110) passes straight through
the valve stop (112) and intake valve (114) installed
in the housing (111) onto the fluid housing (109),
then torque to 298-314 in-lb (35–37 N•m).

Service
16 308302U
5. Apply lubricant to the threads of the screw (145).
Hold the fluid piston (106) steady by inserting a
small screwdriver or punch into the 4mm diameter
hole (A). Install the priming piston (115) onto the
end of the priming piston rod (110), using the screw
(145) and lockwasher (135). Torque to 14-20 in-lb
(1.7–2.3 N•m).
6. Apply lubricant to the top threads of the fluid hous-
ing (109). Screw the air motor coupling (105) onto
the fluid housing, and torque to 298-314 in-lb (35–
37 N•m).
7. Thread the fluid piston (106) into the air motor shaft
(213) until the holes line up. Use the screw (145) to
turn the fluid piston, if necessary. Once the holes in
the air motor shaft and fluid piston are aligned,
insert the pin (144).
8. Lower the pump through the mounting bracket (33).
Orient it in the correct direction and secure to the
bracket using the three screws (38) and washers
(141). Torque the screws to 17-33 in-lb (2–4 N•m).
Reinstall the fluid outlet fitting (28).
9. Reinstall the wiper plate assembly on the fluid
intake housing (111). Secure with the two
cap-screws (302). Reconnect all hoses and return
the pump to service.

235871, Series D Parts - Standard Duty
308302U 17
235871, Series D Parts - Standard Duty
FIG. 8: DynaMite 190 Extruder Assembly Parts without Air Tubing
Ref Part Description Quantity
8 110223 VALVE, vented 2 way 1
13 112338 SCREW, cap, button hd 1
18 110914 VALVE, button, push 1
24 186291 CLAMP, pail 2
25
24
18
13
8
30
28
27
26
27
30
32
32 31
33
34
36
37
38
39
40
40
41
41
42
43
46
47
47
52
52
54
55
55
55
56
56
56
57
58
59
64
64
66
68
69
70
91
97
98
99
100
100
102
106
118
Detail A
Detail B
Detail C
See Detail A above.
See Detail B above
See Detail C above
Part of item 36.
part of item 18.
1
2
3
4
5
1
2
3
4
5

235871, Series D Parts - Standard Duty
18 308302U
* Not shown.
Replacement Danger and Warning labels, tags, and cards are available at no cost.
See page 22.
Ref Part Description Quantity
25 223730 VALVE, assy 1
26 112189 FITTING, y 1
27 110318 REGULATOR, air, 1/4 in. npt 2
28 166866 FITTING, elbow, street 1
30 108190 GAUGE, pressure, air 2
31 100839 FITTING, elbow, street 1
32 110209 NUT, regulator 2
33 188852 BRACKET 1
34 236062 BASE, elevator 1
36 110859 VALVE, air, manual 1
37 110932 CONNECTOR, male 4
38 110873 SCREW, cap, hex hd 3
39 110888 SCREW, wing 2
40 186361 RETAINER, nut 2
41 110874 WASHER, flat 3
42 110933 CONNECTOR, male 1
43 110889 NUT, hex, crown 2
46 100071 NUT, hex 2
47 110911 NUT, hex 4
52 110910 CYLINDER, mount, universal 2
54 109193 FITTING, tube, male, elbow 3
55 198171 FITTING, elbow 4
56 110930 BUMPER, 4
57 110936 FITTING, tee, pipe 1
58 110937 ELBOW, male 1
59 110940 FITTING, adjustable, tee 2
64 110947 WASHER, plain 2
66 186503LABEL, caution 1
68 186502LABEL, caution 2
69 186505LABEL, warning 1
70 186531LABEL, warning 1
91 158019 SHIM, washer 2
97 100975 NUT 1
98 157021 WASHER, lock, int 1
99 111593 SCREW, grounding 1
100 112188 FITTING, elbow 2
102 110249 ADAPTER, male elbow 90 degr 1
106 112186 CONNECTOR, male 1
118 235870PUMP, extruder, sst, 190, series D 1

235871, Series D Parts - Standard Duty
308302U 19
FIG. 9: DynaMite 190 Extruder Assembly Air Tubing Parts
75
77
78
79
80
103
104
105
105
76
Ref Part Description Quantity
75 186532 TUBE, air 1
76 186533 TUBE, air 1
77 186534 TUBE, air 2
78 188963 TUBE, air 1
79 188964 TUBE, air 1
80 188965 TUBE, air 1
103 188966 TUBE, air 1
104 188967 TUBE, air 1
105 188968 TUBE, air 1

25D097, Series A Parts - Heavy Duty
20 308302U
25D097, Series A Parts - Heavy Duty
FIG. 10: DynaMite 190 Extruder Assembly Parts without Air Tubing
etal A
Detail B
Detail C
See Detail A above.
See Detail B above
See Detail C above
Part of item 11.
part of item 20.
1
2
3
4
5
47
46
45
42
43 45
42
43
47
46
39
39
38
38
40
40
41
41
41
41
55
56 41
41
41
53
53
53
53
54
54
65
52
58
57
6
6
9
2
2
23
23
22
33
31
32
30
29
8
7
4
5
3
5
4
3
1
2
3
42
61
28
27
26
16
14
25
16
15
14
13
12
17
10
11
20
34
18
21
19
24
4
5
1
35
36
37
50
51
48
49