Graco Dyna-Star 239882, Dyna-Star 224742, Dyna-Star 224741, Dyna-Star 237653 Instructions Manual

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Page 1

Instructions

™

Dyna-Star

Hydraulic

Reciprocator and Pump

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

308155U

Model 224741, Series C, Stubby Length

1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure 1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet Pressure

Model 224742, Series C,

55 Gallon Length

1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure 1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet Pressure

Model 237653, Series B, Stainless Steel Stubby Length Pump

1000 psi (7 MPa, 70 bar) Maximum Hydraulic Input Pressure 1000 psi (7 MPa, 70 bar) Maximum Fluid Outlet Pressure

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

Page 2

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.

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Page 3

Warnings

WARNING

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 manufacturer’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

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Installation

Grounding

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.

Pump: Use ground wire and clamp as shown in FIG. 1.

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. (F

IG. 1)

FIG. 1

Hydraulic hose and fluid outlet hoses: use only elec-

trically conductive hoses

Hydraulic power supply: Follow manufacturer’s recommendations.

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.

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Page 5

Installation

JKLMN

FIG. 2: Typical Installation

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

* Included in Hydraulic Fluid Control Kit, 236864, which can be ordered separately.

Although the installation shown in F

IG. 2 is only a guide for selecting and installing system components and accesso-

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)

ries, some equipment is required, as noted in the key. For assistance in designing a system to suit your needs, contact your Graco distributor.

Mount the pump to suit the type of installation planned.

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Page 6

Installation

Mount the pump securely so that it cannot move around during operation. Failure to do so could result in personal injury or equipment damage.

Pump Accessories

Carefully follow the manufacturer’s recommendations on cleaning the reservoir and filter and periodically changing the hydraulic fluid.

Hydraulic Power Supply

• 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.

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).

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.

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.

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Page 7

Installation

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 reciprocator/pump seals may need to be changed. (F

IG. 3)

• 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

• Hose: Use a minimum 1/2” supply line (R) and minimum 3/4” return line (F) on the reciprocator. Contact your Graco representative for details of line sizing.

• 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.

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Page 8

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

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.

1. Shut off the hydraulic power.

2. Close the supply line shut-off valve (L, F

3. Open the dispensing valve to relieve pressure.

4. Open the pump outlet drain valve and have a container ready to catch the drainage.

5. Close the return line shut-off valve (H).

NOTE: Leave the drain valve open until you 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.

IG. 2).

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.

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 supply to the reciprocator immediately. Refill the supply container, and prime the pump to eliminate air.

Before Starting the Pump

1. Check the hydraulic fluid level in the hydraulic power supply before each use, and add fluid as necessary to fill the lines.

2. Flush the pump before you use it for the first time to remove the light oil that was left in after factory testing to protect the pump from corrosion. Be sure the solvent used is compatible with the fluid to be pumped and the pump wetted parts. See Technical Data, page 25. Flush until clean solvent comes from the outlet hose.

8 308155U

To prevent the pump from running dry, use a low-level cut off valve (X).

Page 9

Shutdown

self-sealing fitting (1,5,58)

o-ring (1a,5a,58a)

reciprocator

fitting (B or K)

reciprocator

Operation

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 replaceable o-rings. If leaking persists, change the o-rings. (F

IG.

Model 237653: Tighten fittings (B or K). These fittings are self sealing and have replaceable o-rings. If leaking persists, change the o-rings. (F

IG. 5)

self-sealing

o-ring

FIG. 5

FIG. 4

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Page 10

Troubleshooting

Problem Cause Solution

1. Follow Pressure Relief Procedure, page 8, before checking or repairing gun.

2. Check all possible problems and causes before disassembling gun.

Closed dispense valve Pump only runs with valve open.

Pump won’t run

Pump speeds up or runs erratically

Pump runs, but output low on up and/or down stroke

Pump runs but output low on both strokes

Pressure too low

Insufficient hydraulic fluid supply

Clogged fluid outlet line, intake valve, dispense valve, suction line

Reciprocator damaged Repair. See page 11.

Pump piston and/or intake valve is worn

Empty supply container.

Pump piston and/or intake valve worn

Insufficient hydraulic fluid supply

Pressure too low

Clogged fluid outlet line, intake valve, dispense valve, suction line

Increase supply pressure using a pressure adjusting valve.

Check hydraulic supply. Adjust to a maximum of 3 gpm (11 lpm) flow.

Relieve pressure. Check; clear obstruction.

Relieve pressure. Check and repair. See page 11

Refill and reprime. Do not allow pump to run dry. Monitor closely or use a low-level cutoff valve.

Relieve pressure. Check and repair. See page 11.

Check hydraulic supply. Adjust to maximum 3 gpm (11 lpm) flow.

Increase supply pressure using a pressure adjusting valve.

Relive pressure. Check; clear obstructions.

Excessive weepage from weep tube (B)

Hydraulic oil leaks from fittings in the upper or lower reciprocator blocks (31, 32)

10 308155U

Worn throat packings Repair. See page 11.

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.

Page 11

Repair

44*

Torque to 28 to 32 ft-lb (38 to 43 N-m).

216*

16*

Lips face up.

Lips face down.

Lubricate.

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 Procedure, page 8.

2. Disconnect the reciprocator from the pump. See Disconnecting the Reciprocator and Displacement Pump on page 12.

Repair

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 F

IG. 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.

FIG. 6

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 damaging the hydraulic reciprocator. Always install a plug in each tube fitting and on each hoe end whenever fluid lines are disconnected to prevent contamination.

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Page 12

Repair

117

103

118

108

46 (hidden from view)

Models 239882, 224741, and 224742

Model 237653

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 displacement rod in the lowest position.

2. Relieve the pressure, see Pressure Relief Procedure, 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 fittings, and replace them if they are worn or damaged. See F

IG. 4 and FIG. 5 and the Parts Drawing.

6. Unscrew the displacement rod (B) from the reciprocator connecting rod (D).

36,37

5. Using a strap wrench on the displacement cylinder (108), screw it out of the pump adapter (43), and pull it off the pump.

6. Pull the connecting rod (117) down as far as it will go. Remove the cotter pin (118) from the bottom of the displacement rod assembly (34), and unscrew the connecting rod until it is free.

Model 237653

1. Flush the pump if possible, and stop it with the displacement rod in the lowest position.

2. Relieve the pressure, see Pressure Relief Procedure, page 8.

3. If the pump is removed the its mounting, disconnect the hydraulic hoses, and plug all hydraulic connections and lines to prevent contamination.

4. Remove the cotter pin (A) from the top of the displacement rod (B).

5. Loosen and remove the three lock nuts (C), and pull the displacement pump down and away from the motor.

FIG. 7

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Page 13

Reciprocator Repair

36,37

3,39,2

46 (hidden from view)

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 available.

• Assembly tool 189305 is required for reassembling the reciprocator.

Repair

•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 recommendations.

NOTE: Use Loctite

page 14, step 9 only. Use Loctite

609 on yoke (9) and rod (12) on

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 F

IG. 8. If needed,

replace the seals as described in Repair on page

11.

2. Remove the capscrew (3), nuts (36), and lockwashers (37) on top of the reciprocator. (F

IG. 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 prevent contamination. (F

IG. 4 and FIG. 5)

FIG. 8

NOTE: See F

IG. 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 piston (22) to screw it off the rod.

NOTE: Be careful not to scratch the outside of the displacement 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

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Page 14

Repair

36,37

*13

6,7

See

Fig. 8

13*

*24

23*,49*

3,39,2

Torque to 30 to 40 ft-lb (41 to 54 N-m)

(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. (F

IG. 9)

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 Reciprocator Repair Notes on page 13 for specifications. Loctite

609 is used only in STEP 9.

9. Apply fresh Loctite two or three internal threads of the yoke (9). Apply

609 thread sealant to the first

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.

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).

11. Remove the o-ring (13) from the bottom of the spool valve assembly (31), and replace it with a new o-ring.

14 308155U

Torque to 42 to 45 in-lb (4.7 to 5.1 N-m)

FIG. 10

Page 15

Repair

ASSEMBLY B

ASSEMBLY A

FIG. 11

13. Lay Assembly A and Assembly B on the work bench. (F

IG. 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). (F

IG. 11)

screwed about 9/16” into the bottom cylinder cap (32). (F

IG. 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

15. Insert the spring (6) and one ball (7) into the vale stop (26) of Assembly A. Tilt the valve stop, and

place to avoid damage, slide the cylinder over the piston and press it down. (F

IG. 13)

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. (F

IG. 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. (F

IG. 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). (F

IG. 13)

18. If the tie rods (38) were removed, reinstall them with the short threaded end up. The other end should be

308155U 15

When inserting the piston into the cylinder, carefully guide the piston seal (23) and bearing (24) to prevent damaging them.

20. Place the cylinder (25) on the cylinder cap (32). Install the piston (22) and the valve assembly (31).

IG. 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).

NOTICE

Page 16

Repair

118

119*

36,37

*13

13*

3,39,2

Torque to 28 to 32 ft-lb (36 to 43 N-m)

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.

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. (F

IG. 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. (F

IG. 12)

117

103

108

FIG. 12

26. Connect the hydraulic supply and return hoses to the fittings (5, 60).

To reduce the risk of static sparking be sure to re-connect the ground wire before operating the pump.

FIG. 13

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Page 17

Repair

117 103

104

116

115

114

114 106

114

107

115

108

112

109

111

110

118

119

105

0.2 ”

(5 mm)

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

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 F

IG. 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 housing assembly by grabbing the open leg and pulling it toward the center of the housing. Inspect the ball (109) and seat, and replace as needed.

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 leaking, replace the part as needed.

FIG. 14

Intake Valve Reassembly

1. Grease the inside top of the displacement cylinder (108) opening. Thread the guide collar onto the displacement cylinder. Slide the packing a assembly into the collar/cylinder. See F collar guide.

IG. 15. Remove the

308155U 17

Page 18

Repair

117

104

168085 guid

e collar

108

FIG. 15

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 F

IG. 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. (F

IG. 14)

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 reassembling. Inspect the polished surfaces of the displacement rod (7) and cylinder (11) for scratches, scoring or other damage, which can cause premature packing 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

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 reciprocator. 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).

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 displacement 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).

18 308155U

Page 19

6. Insert the displacement rod (7) into the top of the cylinder (11), being careful not to scratch the cylinder. 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 reciprocator by performing the reverse of the disassembly procedure on page 12. (F

IG. 7)

Repair

308155U 19

Page 20

Parts

34a

34b

34c

49*

Ref 46

*44

*16

*13

24*

23*

label

58a

*16

*13

Parts

20 308155U

Page 21

Model 239882, Series A, Hydraulic Reciprocator

Parts

Ref. Part Description Qty.

1 106470 ELBOW, straight thread, 3/4-16

unf-2a x 3/4-16 unf-2a, 37° flare,

includes item 1a 1a† 110987 O-RING 1 2 178179 WASHER, sealing 1 3 106276 CAPSCREW, hex hd, 3/8-24 x 5/8” 1 4 104093 O-RING, nitrile rubber 1 5 112568 ADAPTER, pipe, 3/4 npt(f) 1 6 108437 SPRING, compression, steel 1 7 100069 BALL, 1/4” dia. steel 2 9 189007 YOKE, valve 1 12 192657 ROD, stop, cs 1 13 106274 O-RING, buna-N 2 14 116343 SCREW, grounding 1 16 108952 PACKING, v-block 2 17 105765 O-RING 1 18 114231 LOCKNUT, hex, 1/4-28 unf-3b,

steel and nylon 19 183531 GUIDE, rod, bronze 1 20 192655 RETAINER, spring, cs 2 21† 178189 SPRING, compression, steel 1 22 192656 PISTON, cs 1 23 178226 SEAL, piston 1 24 178207 BEARING, piston, bronze-filled

PTFE 25 178229 CYLINDER, motor, cs 1 26 192654 STOP, valve, cs 1 29 192654 SLEEVE, valve, steel 1 30 178181 PLATE, cap 1 31 239874 SPOOL VALVE ASSEMBLY 1 32 186225 CAP, cylinder, bottom, cs 1 33 183833 BASE, aluminum 1 34 222301 DISPLACEMENT ROD ASSEM-

BLY, contacts 34a to 34c 34a 118078 ROD, displacement 1 34b 105765 PACKING, o-ring 1 34c 178232 STOP, displacement rod 1 36 100307 NUT, full, hex, 3/8-16 unc-2b 4 37 100133 LOCKERWASHER, 3/8” 4 38 187405 ROD, tie, 8.5” shoulder to shoulder,

3/8-16 unc-2a, cs 39 155685 O-RING 40 179885 LABEL, warning 1 43 183533 ADAPTER, pump, cs 1 44 108951 SEAL, polyester elastomer 1 45 217221 TUBE, inlet 1 46 108986 CAPSCREW, sch, 3/18-16 unc-2a

x 4.5” 49 108014 O-RING, buna-N 1 51 104092 CAPSCREW, sch, 10-24 unrc-3a x

5/8”

Ref. Part Description Qty.

52 106115 LOCKWASHER, spring 3/8” 4

58 107197 TEE, includes item 58a 58a† 110987 O-RING 1 59 110064 PLUG, pipe, vented, 1/8-27 nptf 1 60 112569 UNION, swivel, steel 1

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

 Parts included in Kit 223426 (purchase separately).

† Keep these parts on hand to reduce downtime.

Assembly tool 189305 required for repairing the recip-

rocator.

308155U 21

Page 22

Parts

117

103

104

116

115

113

114

106

107

119*

108

112

109

111

110

118

201

101

202a

202b

Label

105

114

113

115

Model 224741, Series C, Universal 1:1 Ratio Pump, Includes items 101 to 120 Model224742, Series C, Hydraulic Reciprocator, Includes items 201 and 202

Qty

Ref. Part Description

101 239882 HYDRAULIC RECIPROCATOR,

see parts on page 19 103 100111 NUT, hex jam, 1/2-20 1 104 157184 HOUSING, piston 1 105† 154662 O-RING, buna-N 1 106 158857 SPACER, fluid piston packing 1 107 156989 SEAT, piston 1 108 183010 CYLINDER, displacement 1 109 101190 BALL, steel, 1” (25 mm) dia 1 110 183009 BODY, valve 1 111 156633 O-RING, nitrile rubber 1 112 157182 RETAINER, ball 1 113† 171590 WASHER, spreader 2 114† 158402 PACKING, leather cup 2 115† 171594 WASHER, back-up 2 116 100279 STEEL, ball 0.88” (22.2 mm) dia 1

Ref. Part Description

117 183529 ROD, connecting 1 118 100103 PIN, cotter, 0.125” (3.2 mm) dia,

1.5” (38 mm) long

119 108993 O-RING, buna-N 1 120 183741 LABEL 1 201 224741 1:1 RATIO DYNA-STAR RECIP-

ROCATOR PUMP, See 101 through 120

202 222346 DROP TUBE, includes items 202a

and 202b 202a 185151 TUBE 1 202b 110127 SPACER, foot 1

 Parts included in Kit 223426 (purchase separately).

† Keep these parts on hand to reduce downtime.

Qty

120

22 308155U

Page 23

41*

39*

Apply primer and Loctite TL222, and torque to 42 to 45 in-lb (4.7 to 5.1 N

Torque to

28 to 30

ft-lb

(36 to 41

24*

23*

17* 20

21*

18*

34a

13*

15*

43*

press

fit

37 30

*13

34b

34c

Model 237653, Series B

Qty

Ref. Part Description

1 239874 CYLINDER CAP ASSY, upper 1 2 178179 WASHER, sealing 1 3 106276 CAPSCREW, hex hd, 3/8” thd x

0.625” long

4 104093 O-RING, nitrile rubber 1 6 108437 SPRING, compression, steel 1 7 100069 BALL, steel, 1/4” dia 2 9 189007 YOKE, valve 1 12 192657 ROD, trip 1 13 106274 O-RING, buna-N 3 15 109194 V-PACKING, block 1 17 105765 O-RING, buna-N 2 18 114231 LOCKNUT, hex, 1/4-28 unf-3b,

steel/nylon 19 178185 BEARING, sleeve 1 20 192655 RETAINER, spring, cs 2 21 178189 SPRING, compression, steel 1 22 192656 PISTON, cs 1 23 178226 SEAL, piston, glass filled PTFE 1 24 178207 BEARING, piston, bronze-filled

PTFE 25 178229 CYLINDER, motor, cs 1 26 192654 STOP VALVE, cs 1 29 189072 SLEEVE, valve, steel 1 30 178181 PLATE, cap 1 32 178235 CAP, cylinder, bottom 1 33 178233 RETAINER, housing 1 34 222301 DISPLACEMENT ROD ASSY,

includes 34a to 34c 34a 188078 ROD, displacement 1 34b 105765 PACKING, o-ring 1 34C 178232 STOP, displacement rod 1 36 106292 NUT, hex, 3/8” thread 4 37 100133 WASHER, lock, 3/8” 4 38 178228 ROD, tie, 12/28” (312 mm), cs 4 39 155685 O-RING, buna-N 1 40 179885 LABEL, warning 1 41 108014 O-RING, buna-N 1 42 CAPSCREW, sch, 10-24 unrc-3a x

5/8” 43 183915 WASHER 1

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

 Parts included in Kit 218210 (purchase separately).

308155U 23

Parts

Page 24

23*

24*

25*

26*

30*

27*

25*

Parts

Model 237653, Series B

NOTE: Reciprocator/pump Model 237653, Series B,

has displacement pump Model 224344, Series F, which is shown here.

Ref. Part Description

1 100063 PIN, cotter, 1/16” x 1/2”, sst 2 2 101917 BALL, 0.875” (22 mm), sst 2 4 164782 O-RING, PTFE 1 5 162947 PIN, ball stop, intake, sst 1 6 186987 GLAND, throat, male, sst 1 7 186997 ROD, displacement, sst 1 8 186988 GLAND, throat, female, sst 1 9 166133 V-PACKING, throat, female, sst 2 10 176637 PIN, ball stop, piston, sst 1 11 186994 CYLINDER, sst 1 12 164846 O-RING, PTFE 1 13 186992 HOUSING, valve, intake, sst 1 14 186993 STUD, piston, sst 1 15 186995 PACKING NUT/WET-CUP, sst 1 16 205999 HOUSING, outlet, sst 1 17 164630 RING, locking, sst 1 19 170625 V-PACKING, throat, UHMWPE 1 22 164679 GUIDER, ball, intake, sst 1 23 176634 WASHER, piston, sst 1 24 186990 GLAND, piston, male, sst 1 25 176638 V-PACKING, piston, UHMWPE 2 26 111293 V-PACKING, piston, neoprene 1 27 186989 GLAND, piston, female, sst 1 28 176644 STUD, mounting, piston, sst 1 30 111790 SHIM, sst 1

 Parts included in Kit 224402 (purchase separately).

Qty

*19

*10

24 308155U

Page 25

Technical Data

Dyna-Star

Maximum Hydraulic Fluid Input Pressure and Maximum Fluid Output Pressure

Models 239882, 224741, and 224742 1500 psi 10 MPa, 102 bar Model 237653 1000 psi 6.9 MPa, 69 bar

Maximum Hydraulic Fluid Input Volume

Fluid Consumption Rate 6.5 ounces per cycle or 1 gal-

Maximum Fluid Temperature 130°F 55°C Pressure Reducing Valve Adjustment Range 50 to 1500 psi 0.34 to 10 MPa, 3.4 to 102 Bar Effective Piston Area

Piston Rod Diameter 1.375 in. 34.9 mm Output Per Cycle 0.055 gpm with No. 30 oil at 60 cpm Stroke 4 in. 101.6 mm Thrust at 1000 psi (6.9 MPa, 69 bar) 1480 lb 673 kg Maximum Suction Lift 13 ft 4 m Displacement Pump Wetted Parts Steel, Copper, Leather Weight 24 lb 11kg Sound Pressure* 77 dB(A)

™

US Metric

6 gpm

11.7 lpm

0.195 liters per cycle or 1 gal-

lon per 19.5 cycles

1.48 in.

lon per 19.5 cycles

9.55 cm.

* Sound pressure reading taken with pump operating at 66 cycles per minute. Sound pressure measured per

CAGI-PNEUROP, 1971.

Loctite® is a registered trademark of the Loctite Corporation.

308155U 25

Page 26

Dimensions and Mounting Hole Layout

3.536 in. (90.424 mm)

3 in (76.2 mm) minimum diameter clearance hole

Clearance for, OR tap 5/16–18, Typical 4 places

NOTE: Pump body orientation is

square with mounting holes.

3.536 in. (90.424 mm)

8.62 in.

(219 mm)

Displacement

Pump

23.37 in.

(594 mm)

Model 224741

34.3 in.

(871 mm)

Displacement

Pump and

Drop Tube

3/8 npt(f) hydraulic supply port

Fluid Inle (Stubby Pump) 1-1/2” NPT for models 224741, 224742 3/4” NPT for model 237653

14.75 in.

(375 mm)

Reciprocator

Model

239882

and

217222

3/4 npt(f) hydraulic return port

1/2 npt(f) fluid outlet port

49 in.

(1245 mm)

Model 224742

Dimensions and Mounting Hole Layout

26 308155U

Page 27

Notes

308155U 27

Page 28

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 308155

International Offices: Belgium, China, Japan, Korea

Graco Headquarters: Minneapolis

www.graco.com

Revised September 2014