Loctite AC988557 User's Manual
Contents
1. 8 Pump Repair Kit P N AC244092 Item 92 includes items 55 56 62 63 64 65 a 7 14 Soft Parts Kit P N 988751 for repair of Power Valve Subassemblies 2 Soft Parts Kit P N 988746 for repair 9 Bleed Assembly P N AC273428 listed above of Pump Stop Subassembly See Item 67 includes items 73 through Parts List for contents 89 15 Power Valve Spool amp Body P N 988750 3 Relay Valve P N 988748 Item 17 4 Signal Valve Cap Kit P N AC243853 Item 31 includes Item 32 10 Gasket and Air Filter Kit Item 89 P N AC273427 Items 40 51 amp 53 9 A Signal Valve P N 988749 Item 11 Gasket Plate with Check Valves Item 90 P N AC244093 Items 52 amp 63 g cd 50 6 Trip Indicator P N AC243852 Item 0 48 fe fe Page Number 4 FOR STANDARD AIRMOTOR A WARNING ALWAYS check equipment for proper operation before each use making sure safety devices are in place and operating properly DO NOT alter or modify any part of the equipment as this may cause a malfunction and result in serious bodily injury BEFORE CONNECTING AIRMOTOR TO AIR LINE LOCTITE AIRMOTORS are fully pneumatic and require a minimum specified size of air supply hose for proper operation Check specification for minimum ID of the air supply hose and select corresponding sizes of air controls and accessories for2. Fi E Operation Manus AUR Loctite amp Airmotors Part Numbers 988526 4 1 4 Airmotor D 988528 6 Airmotor 988545 Pump Stop 988552 Low Level Micro Switch IT IS THE RESPONSIBILITY OF THE OWNER AND OR OPERATOR TO PROPERLY USE AND MAINTAIN THIS EQUIPMENT CAREFULLY READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THIS MANUAL BEFORE OPERATING THIS EQUIPMENT If the operator is not fluent in English the instructions and warnings shall be read and discussed in the operator s native language making sure the operator comprehends the contents This equipment complies with OSHA Standards where applicable A WARNING DO NOT exceed the stated maximum working pressure of the airmotor or of the lowest rated component in your system DO NOT alter or modify any part of this equipment DO NOT operate this equipment with combustible gas DO NOT attempt to repair or disassemble the equipment while the system is pressurized TIGHTEN all fluid connections securely before using this equipment ALWAYS read and follow the fluid manufacturer s recommendations regarding fluid compatibility and the use of protective clothing and equipment CHECK all equipment regularly and repair or replace worn or damaged parts immediately IMPORTANT Failure to heed these warnings including misuse overpressurizing modifying parts using incompatible chem
3. 4 Included in 988753 Cylinder Tube Soft Parts 36 Adapter 241789 Kit for Part No 988528 6 Airmotor 37 Screw 1 4 20x2 4 244975 244975 2 included in 988752 Cylinder Tube Soft Parts 38 Couper 1 Aces5012 26655008 for Part No 988526 4 1 4 Airmotor 39 Screw 6 32 2 AC50816 50816 3 Included in 988746 Soft Parts Kit for Pilot Bar 40 Screw 14 20 a 255083 2650823 Subassembly Pai TieRod 26241023 26241023 lt Soft Parts KI for Power 43 Wufler i 26273507 273507 Body 44 Npple 1 AC653112 26653112 45 Hibow i 2587062 AC87082 fums Unused 2 Moers 4 O ring Buna N O ring Buna N Note 3 Note 3 1 1 2 2 1 4 1 2 4 4 4 1 1 1 2 4 Page Number 14 PARTS LIST FOR AIRMOTORS WITH PUMP STOP Part No Part No Part No Part No Description 988528 988526 Description 988528 988526 6 Dia 474 Dia 6 Dia 4 7 50 T Gef Note 2 55 Oring 2 Noea KNIE aaa nara 3 Seal Cylinder Buna N 2 Note 1 Note 2 37 Screw 7220270 4 AC244975 6244975 6 Cyinder Tube 1 AC241745 AC241746 40 Ar Fier 2 Note 5 Note 5 8 Upper Casing 1 AC241751 241752 42 NutQz 20j AC236203
4. 1 Remove Pilot Bar Subassembly See previous instructions 2 Remove two Screws Item 30 with 3 16 hex wrench and re move muffler subassembly Remove Gasket Items 28 Remove four Nuts Item 26 with open end wrench Lift upward and remove Upper Casting Item 8 Remove four Tie Rods Item 25 Remove Air Tube Item 7 Lift upward and remove Cylinder Tube Item 6 Remove Piston and Piston Rod Item 5 10 Remove four Connecting Rods Item 41 with open end wrench 11 To REASSEMBLE REVERSE procedure x Or de NOTE Align two holes on the the Cylinder Tube Item 6 with two holes on the Pilot Bar Item 24 before tightening Tie Rods Item 25 so that proper seal with O rings is acheived Page Number 5 FOR AIRMOTOR WITH PUMP STOP A WARNING ALWAYS check equipment proper operation before each use making sure safety devices are in place and operating properly DO NOT alter or modify any part of the equipment as this may cause a malfunction and result in serious bodily injury BEFORE CONNECTING AIR MOTOR TO AIR LINE LOCTITE AIRMOTORS are fully pneumatic and require a minimum specified size of air supply hose for proper operation Check specification for minimum ID of the air supply hose and select corresponding sizes of air controls and accessories for non restrictive air flow If quick disconnect coupling should be used install supplied coupler to insure proper airmotor
5. 02 5 5 TARE o s o p ojo o S IE a go o 5 5 5 Q Page Number 16 Setting the Pump Stop Speed LOCTITE ra Suis Speed Setting E Legend Speed Setting Dial Illustration 1 Settings A Run mode Pump Stop is disabled Air motor will continue to run at any speed 35 to 45 Cycles per Minute Pump Stop will trip turning off the air motor when the air motor speed reaches a speed of 35 to 45 cycles per minute 25 to 35 Cycles per Minute Pump Stop will trip turning off the air motor when the air motor speed reaches a speed of 25 to 35 cycles per minute 20 to 30 Cycles per Minute Pump Stop will trip turning off the air motor when the air motor speed reaches a speed of 20 to 30 cycles per minute 15 to 25 Cycles per Minute Pump Stop will trip turning off the air motor when the air motor speed reaches a speed of 15 to 25 cycles per minute 10 to 20 Cycles per Minute Pump Stop will trip turning off the air motor when the air motor speed reaches a speed of 10 to 20 cycles per minute 5 to 15 Cycles per Minute Pump Stop will trip turning off the air motor when the air motor speed reaches a speed of 5 to 15 cycles per minute Note These speed settings are not precision speed control settings for the air motor All speed settings are approximate and are not intended for use in precisely controlling the speed
6. 6236203 9 Bumper Vane 2 Note 3 Note 3 43 1 273507 6273507 2 Boy Vale 1 Note 10 46 Spook vae 1 Note 10 Note 10 47 ELI UL JEU CORN 21 Oning Fiston BuneN Note 55 Pison _ ote Note 8 22 LowerCas ng 1 AC241774 AC241775 56 Pump Sleeve 8 Note 8 Geax TAT cest Aces 7 Reister 1 odo 24 Screw lt 20x716 4 AC50850 50850 58 Diaphragm 1 Note 9 Note 9 Cm Teed 1 tese 4 51007 51001 60 Stop Valve Assembly 1 Note 9 Note 9 2 46284985 46284985 61 Diaphragm Seal 7 Note fo No 35 28 62 11 Nae 29 Mufer Adapter 1 AC84722 ACB4722 63 Umbrella Seal Nit 2 7 amp 8 Note 7 amp 8 30 Screw 14 20 x 1 17 32 Screw 8 32 508 4 Note 6 Note 6 66 SpringPin 2 AC243614 Ac243614 Fss Sea Pison _ 2 642 67 Bleed Assembly 1 AC243854 AC243854 NOTES 1 Included in 988753 Cylinder Tube Soft Parts 6 Included in AC243853 Signal Valve Cap Kit Kit for Pa
7. Erratic or accelerated operation with short stroking Airmotor hesitates on up or down stroke Pump Stop trips off even though airmotor is operating below set trip speed Trips after three or more strokes Pump Stop trips even though airmotor is operating below set trip speed within three strokes Pump Stop trips at proper speed as indicated by the sound of air surging into the diaphragm chamber but airmotor does not stop indicator pin does not pop out Pump Stop will not trip even though airmotor has been running above the trip speed for more than 1 minute Page Number 18 POSSIBLE CAUSE SOLUTION Inadequate air supply to airmotor Check air supply and adjust to minimum recommended level Check air supply hose and piping for minimum recommended size Ensure that FRL and quick disconnect couplings meet or exceed the minimum specified sizes and do not restrict airflow to the airmotor Dirty or damaged Relay Valve Item 17 Check valves and clean if necessary or Air Signal Valve Item 20 or stop valve Replace any damaged seals or worn parts assembly Item 60 Pump Cavitation Check Fluid Level Ensure that pump inletis not blocked or restricted or is large enough to handle flow into pump inlet Dirty or blocked labyrinth plate or components Clean or replace labyrinth components Check for grease or oil blocking air passages in labyrinth subassembly A blocked labyrinth may be confirmed quiet location
8. repairing any part of Airmotor Tools Required 7 64 109 Allen Wrench 5 32 156 Allen Wrench 3 16 189 Allen Wrench 1 8 125 Allen Wrench 9 64 1406 Allen wrench 3 4 750 Open End Wrench for 6 Air motor 1 Phillips screwdriver 1 2 500 Open End Wrench 1 2 500 Box End Wrench 10 Pliers 11 0 100 in Ib Torque Wrench 12 0 75 Ft Ib Torque Wrench The modular design of the Airmotor and accessibility of vital operation parts make service available without taking Airmotor out of line or without complete disassembly Power Valve 1 Remove four screws Items 27 amp 34 with 3 16 hex wrench 2 on each side Remove End Caps Items 10 amp 14 Push out Valve Spool Item 13 Remove Spool Bumpers Item 9 One from each end Boom Page Number 6 5 Remove O Ring Item 11 One from each end of valve body 6 Remove four Screws Item 37 with 3 16 hex wrench and lift valve body Item 12 7 Remove Gasket Item 15 to complete valve disassembly 8 REASSEMBLE REVERSE procedure Optional Pump Stop Subassembly 1 Remove four Screws item 23 two on each end with 3 16 Allen wrench and pull out Pump Stop Subassembly 2 Remove two Screws Item 39 with 7 64 Allen wrench and lift out Valve Body item 17 3 Remove four Screws Item 32 two on each side of Pump Stop with1 8 Allen wrench and remove Signal Valve C
9. of a pump pump tube combination Precision control of the pump operating speed is beyond the scope of this device Remove the selector cover item 87 by removing screw item 88 to gain access to the selector knob item 84 Select the RUN mode by positioning the selector knob pointer a small round hole in the face of the selector knob to the letter R on the face of the labyrinth cover item 78 With the pump and air motor operating normally determine the speed of the pump by counting the number of strokes the pump makes per minute 4 After determining the normal operating speed of the pump and air motor consult the Setting legend on the face of the Labyrinth cover item 78 and find the speed range that is closest to the normal operating speed of the air motor 5 To allow for normal fluctuation in the operating speed of the air motor and pump set the selector knob to the next highest speed setting 6 Test the pump in operation to make sure that it is operating normally before leaving the pumping system unattended WARNING Always shut off air supply before servicing Airmotor An Airmotor in the tripped condition is under pressure and may restart unexpectedly for one or two cycles Pump Stop Operation Selecting a speed range letter other than R will activate the Pump Stop as discussed earlier The Pump Stop will Trip stopping the air motor from operating if the threshold speed setting is exc
10. operation NOTE Whenever flammable materials are pumped ground Airmotor accord ing to Local Codes OPERATING PRECAUTIONS Use Loctite replacement parts to assure compatible pressure rating Heed ALL warnings DO NOT OPERATE Airmotor in excess of recommended pressure range Disconnect air line and relieve vent pressure when Airmotor sits idle for long periods of time and before servicing WARNING ALWAYS read and follow the fluid and solvent manufacturer s recommendations regarding the use of protective clothing and equipment A warnine To reduce the risk of serious bodily injury or property damage NEVER exceed the maximum air or fluid working pressure of the lowest rated system component ATTACHING AIRMOTOR TO PUMPTUBE 1 Tightly attach the tie rods Item 41 to the Airmotor lower casting Use short threaded end of tie rods 2 Mount Airmotor on top of pump tube outlet and tightly connect pump tube coupling nut to Airmotor Piston Rod Item 5 3 Hand tighten tie rods to the pump tube with four nuts Item 42 supplied with Airmotor 4 Connect air supply and slowly cycle pump several times using only enough air pressure to operate pump without stalling 5 STOP pump on stroke and tighten four nuts to securely fasten Airmotor to pump tube SERVICE AND DISASSEMBLY PROCEDURE Always disconnect air supply to Airmotor and relieve pressure before checking servicing or
11. RRANTY OF ANY KIND WHATSOEVER EXPRESS IMPLIED WITH RESPECT TO THE PRODUCTS ALL WARRANTIES OF MERCHANTABILITY FITNESS FORA PARTICULAR PURPOSE AND OTHER WARRANTIES OF WHAT EVER KIND INCLUDING AGAINST PATENT OR TRADEMARK INFRINGEMENT ARE HEREBY DISCLAIMED BY HENKEL AND WAIVED BY THE PURCHASER THIS SECTION SETS FORTH EXCLUSIVELY ALL OF LIABILITY FOR HENKEL TO THE PURCHASER IN CONTRACT IN TORT OR OTHERWISE IN THE EVENT OF DEFECTIVE PRODUCTS WITHOUT LIMITATION OF THE FOREGOING TO THE FULLEST EXTENT POSSIBLE UNDER APPLICABLE LAWS HENKEL EXPRESSLY DISCLAIMS ANY LIABILITY WHATSOEVER FOR ANY DAMAGES INCURRED DIRECTLY OR INDIRECTLY IN CONNECTION WITH THE SALE OR USE OF OR OTHERWISE IN CONNECTION WITH THE PRODUCTS INCLUDING WITHOUT LIMITATION LOSS OF PROFITS AND SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES WHETHER CAUSED BY NEGLIGENCE FROM HENKEL OR OTHERWISE Henkel Corporation Henkel Canada Corporation Henkel Capital S A de C V 1001 Trout Brook Crossing 2225 Meadowpine Boulevard Calzada de la Viga s n Fracc Los Laureles Rocky Hill CT 06067 3910 Mississauga Ontario L5N 7P2 Loc Tulpetlac C P 55090 Ecatepac de Morelos Edo de M xico Henkel Automotive Henkel Ltda Technology Center Rua Karl Huller 136 Jd www loctite com 2455 Featherstone Road Canhema 09941 410 Auburn Hills Michigan 48326 Diadema SP Brazil Loctite is a registered trademark of Henkel Corporation U S A Copyright 2004 Henkel Corporation All rights r
12. airmotor After removal the faulty assembly can then be repaired using the corresponding Soft Parts Kit 6 Power Valve Subassembly 1 Pilot Bar Subassembly P N AC244806 6 Airmotor P N 988747 P N AC244808 4 1 4 Airmotor 7 Soft Parts Kit P N 988751 for repair of Power Valve Subassemblies listed above 2 Soft Parts Kit P N 988746 for repair of Pilot Bar Subassemblies listed above Includes necessary O rings 3 Relay Valve P N 988748 5 Cylinder Tube Soft Parts Kit Includes all piston seal etc P N 988753 6 Airmotor P N 988752 4 1 4 Airmotor IMPORTANT When replacing soft parts replace all parts included in the soft parts kit Page Number 3 FOR AIRMOTORS WITH PUMP STOP SERVICE ASSEMBLIES amp KITS To reduce down time and take advantage of the modular design of the airmotor Henkel recommends using the following Service Assemblies for repair of the airmotor After removal the faulty assembly can then be repaired using the corresponding Soft Parts Kit 7 Stop Valve Repair Kit P N AC 12 Cylinder Tube Soft Parts Kit 1 Pump Stop Subassembly 244091 Item 91 includes items Includes O rings piston seal P N 988545 57 58 59 60 61 etc P N 988753 6 Airmotor P N 988752 4 1 4 Airmotor Oe N D 13 Power Valve Subassembly P N AC244806 6 Airmotor Q P N AC2448068 4 1 4 Airmotor lt
13. aps Item 31 and Air Signal Valves Item 20 4 Remove four 4 screws item 80 with 9 64 Allen wrench to remove labyrinth sub assembly from Pump Stop 5 Remove four Screws Item 24 with 3 16 Allen wrench and lift off Upper Body Item 50 and Upper Gasket Item 51 6 Remove Gasket Plate Item 52 and Lower Gasket Item 53 7 Remove Air Filter Item 40 in two locations 8 Remove Pump Sleeve Item 56 and Piston Item 55 9 Remove Diaphragm Seal and Retainer Diaphragm Spring and Stop Valve Assy Items 61 57 58 59 amp 60 10 Remove Trip Indicator Item 48 11 To re assemble reverse the disassem bly procedure with the following precautions a The upper and lower gaskets items 51 amp 53 should be coated with a film of light oil SAE 10 before assembly b When new umbrella valves item 63 are installed note that the gasket plate item 52 has a circle and an X stamped into both sides of the gasket plate The umbrella valve is installed into the plate from the circle side of the plate One umbrella valve should be installed into each side of the plate so that the valve is within the circle and the stub end protrudes through the X c After installing the umbrella valve item 63 the long rubber stem of the valve is to be removed leaving the rubber ball end intact to secure the valve to the plate d When installing the pump sleeve item 56 into the lower body item 54 the sleeve s
14. eeded The air motor will not restart until it is intentionally reset The cause of a pump OVERRUN may be anything that will allow the pump to run faster than normal such as but not limited to the following Cavitation Low fluid levels will allow the pump to cavitate where the pump is trying to pump air instead of fluid into the fluid lines Broken Hose or Fitting will cause a loss in fluid pressure allowing the pump to run faster than normal Increase in Air Pressure Either sudden or gradual may cause a pump operating from an air supply system which is marginal or inadequate for the application to rise as other equipment in the plant is shut down thus making more air available to the pump to operate with Unauthorized tampering with an air pressure regulator may also be a cause Increase in Demand Fluid demand may be greater than expected A tripped condition can be determined if the air motor has stopped the RED ORANGE indicator pin will be out see Illustration 2 the pump rod will be in the down position and air will be heard venting from the VENT HOLE in the lower body of the Pump Stop See Illustration 4 Before resetting the cause of the OVER RUN should be determined if possible before restarting the pump Check for low Tripped Run iti ur Condition Position Extended Illustration 2 fluid levels broken hose or fitting connec tions before restarting If a cause cannot be determined without s
15. eserved Data in this operation manual is subject to change without notice Page Number 20
16. hould be placed into the lower body as shown in Illustration on Page 12 When properly installed the molded pin protruding from the pump sleeve will fitinto a mating hole in gasket item 53 and the gasket can then be installed properly over pins item 66 If the sleeve is not properly aligned as shown the Pump Stop cannot be assembled properly Labyrinth Sub Assembly Disassembly Procedure 1 Use 9 64 Allen wrench to remove four screws item 80 from the face of the labyrinth sub assembly to remove it from the Pump Stop assembly 2 Remove screw item 88 using a 1 Phillips screwdriver to remove the cover item 87 over the selector knob 3 Remove the selector bolt item 86 and washers item 85 to remove the selector knob Use caution when removing the selector knob from the labyrinth assembly a pin item 82 spring item 83 and 7 balls item 81 are retained by the selector knob and could be lost 4 Remove gasket item 74 from the backside of the labyrinth sub assembly 5 Using a 9 64 Allen wrench remove six screws item 73 from the backside of the labyrinth sub assembly 6 Separate the labyrinth sub base item 75 from the labyrinth cover item 78 exposing the labyrinth plate and gasket 7 Remove the gasket item 76 and plastic laminated labyrinth item 77 8 Remove seven O rings item 79 from the labyrinth cover item 78 Labyrinth Sub Assembly Re assembly Procedure Re assembly is basical
17. icals and fluids or using worn or damaged parts may result in equipment damage and or serious personal injury fire explosion or property damage This manual contains IMPORTANT WARNINGS and INSTRUCTIONS READ AND RETAIN FOR REFERENCE JULY 2004 Copyright 2004 Form 403504 Printed U S A Qenka Technologies NOTE DO NOT OPERATE with air contaminated with materials not compatible with BUNA N seals 2 1 8 Pump Stop SPECIFICATIONS CYLINDER EFFECTIVE OPERATING OPERATING MIN ID AIRINLET AIR CONS 100 ITEM DIAMETER PISTON PRESSURE TEMP RANGE OFAIR PSIG 7 BAR AREA RANGE F C SUPPLY SCFICYCLE IN CM PSIG BAR IN MM L N CYCLE 988528 6 152 28 182 30 100 2 7 30 200 12 12 3 4 NPTF 1 6 46 988526 4 1 4 108 14 92 30 100 2 14 34 93 1 2 12 1 2 NPTF 1 1 32 STROKE ITEM RECOM LENGTH WEIGHT SEALS DIM C IN MM LB KG MATERIAL IN MM 988528 75 6 152 34 155 BUNAN and 11 1 8 283 7 3 4 197 22 3 4 577 988526 26 11 7 TEFLON 9 3 8 238 6 5 8 168 23 5 8 599 TEFLON Seals used with Power Valve Spool Item 13 and Relay Valve Item 17 Page Number 2 FOR STANDARD AIRMOTOR WITHOUT PUMP STOP SERVICE ASSEMBLIES amp KITS To reduce down time and take advantage of the modular design of the airmotor Henkel recommends using the following Service Assemblies for repair of the
18. insurance charges paid therefor by the user The purchaser s sole and exclusive remedy for breach of warranty shall be such replacement or credit A claim of defect in materials or workmanship in any Products shall be allowed only when it is submitted in writing within one month after discovery of the defect or after the time the defect should reasonably have been discovered and in any event within 12 months after the delivery of the Products to the purchaser This warranty does not apply to perishable items such as seals wipers fuses filters etc No such claim shall be allowed in respect of products which have been neglected or improperly stored transported handled installed connected operated used or maintained In the event of unauthorized modification of the Products including where products parts or attachments for use in connection with the Products are available from Henkel the use of products parts or attachments which are not manufactured by Henkel no claim shall be allowed No Products shall be returned to Henkel for any reason without prior written approval from Henkel Products shall be returned freight prepaid in accordance with instructions from Henkel NO WARRANTY IS EXTENDED TO ANY EQUIPMENT WHICH HAS BEEN ALTERED MISUSED NEGLECTED OR DAMAGED BY ACCIDENT OR IF THE SYSTEM WAS USED TO DISPENSE ANY LIQUID MATERIAL OTHER THAN HENKEL PRODUCTS EXCEPT FOR THE EXPRESS WARRANTY CONTAINED IN THIS SECTION HENKEL MAKES NO WA
19. items 55 56 63 64 amp 65 Inlet Air Filter Irem 40 is completely or Clean or replace inlet air filter partially clogged P N 988552 LOW LEVEL MICROSWITCH KIT AC 244397 Switch Bracket AC69360 Limit Switch Pump Stop t Trip Indicator Plug Trip Indicator Pin INSTALLATION INSTRUCTIONS In Run position 1 Remove Trip Indicator Plug from Pump Stop Install the B E Switch Bracket in position shown on Pump Stop and Limit Switch 1 secure by reinstalling Trip Indicator Plug Plunger 2 Using the two mounting screws washers and nuts assemble the 69360 Limit Switch in up position as Switch shown to Switch Bracket loosely Bracket 3 Adjust Limit Switch to provide a 050 clearance between Limit Switch Plunger and Trip Indicator Pin with pin in Run position Tighten mounting screws securely to hold switch in place 050 Clearance SWITCH ADJUSTMENT Page Number 19 WARRANTY Henkel expressly warrants that all products referred to in this Instruction Manual for Item 988526 Air Motor 988528 Air Motor 988545 Pump Stop 988552 Low Level Micro Switch hereafter called Products shall be free from defects in materials and workmanship Liability for Henkel shall be limited as its option to replacing those Products which are shown to be defective in either materials or workmanship or to credit the purchaser the amount of the purchase price thereof plus freight and
20. ly the reverse of the disassembly procedure with the following precautions 1 Insure that the plastic laminated labyrinth item 77 is in good condition before re assembly The clear plastic laminate should be in sound condition without any tears or indications of separation from the brass labyrinth plate inside Visually inspect the labyrinth plate for any sighs of blockage including but not limited to dirt grease oil or water which should be visible through the clear laminating material 2 Keep all labyrinth components clean and free of grease oil and dirt except as noted 3 A very light coating of light grease may be used to retain the balls item 79 in place when installing the selector knob item 84 4 When reassembling the labyrinth sandwich install the six screws item 73 but do not tighten Install the selector knob item 84 and selector bolt item 86 before tightening the six screws item 73 Tighten the six screws item 73 to 12 in lbs Tighten the selector bolt item 86 to 50 in Ibs 5 When installing the labyrinth sub assembly onto the Pump Stop assembly use four screws item 80 and tighten to 12 in Ibs Tube and Muffler Remove Pump Stop Subassembly See previous instructions 2 Remove two Screws Item 30 with 3 16 hex wrench and remove Muffler Assembly 3 Remove Gasket Items 28 4 Remove four Nuts Item 26 with open end wrench 5 Lift upward and remove Uppe
21. non restrictive air flow If quick disconnect coupling should be used install supplied coupler to insure proper airmotor operation NOTE Whenever flammable materials are pumped ground Airmotor according to Local Codes OPERATING PRECAUTIONS Use Loctite replacement parts to assure compatible pressure rating Heed ALL warnings DO NOT OPERATE Airmotor in excess of recommended pressure range SERVICE AND DISASSEMBLY PROCEDURE A WARNING Always disconnect air supply to Airmotor and relieve pressure before checking servicing or repairing any part of Airmotor TOOLS REQUIRED 7 64 109 Hex Wrench 5 32 156 Hex Wrench 3 16 189 Hex Wrench 3 4 750 Open End Wrench for 6 Airmotor 1 2 500 Open End Wrench for 4 1 4 Airmotor Pliers Q9 gr og The modular design of the Airmotor and accessibility of vital operation parts make service available without taking Airmotor out of line or without complete disassembly Power Valve 1 Remove four screws Items 27 amp 34 with 3 16 hex wrench 2 on each side Remove End Caps Items 10 amp 14 Push out Valve Spool Item 13 Remove Spool Bumpers Item 9 One from each end Remove Ring Item 11 One from each end of valve body Remove four Screws Item 37 with 3 16 hex wrench and lift valve body Item 12 Remove Gasket Item 15 to complete valve disassembly To REASSEMBLE REVERSE procedure Disconnec
22. om ye CS al e App Note Single hole on Item 76 should align with single hole 79 on Item 75 74 Item 67 Detail Assembly Page Number 11 Note holes at 9 amp 6 o clock positions Molded pin on pump sleeve Position to about 7 O Clock position as shown Page Number 12 AIRMOTOR WITH PUMP STOP 10 12 Ft Lbs Torque to a o 2 Ea c o 3 a N o a D o 5 oO o 2 2 o E 5 u a w e X Td 90 292 Eos ae 95 gt B nS Wa 50 9 32 1 u t x 36 irmotor Only 1 4 A 4 20 31 Y H 2 T 4 7 ML 2 4 23 Be DAE 24 T NIS N Nes 7 NS GUN 27 E di 7 Page Number 13 PARTS LIST ARMOTOR WITHOUT PUMP STOP Description Qty Part No 988528 Part 988526 FN d 6 Cyinder Tube AC241745 AC241746 8 UpperCastng i AC241751 AC241752 9 Bumper vae 2 Notef4 21 Oring Piston BunaN i 3 Bracket Upper i AC241784 25241784 32 Bracket Lower AC241785 AC241785_ Parts List Notes 33 Seal Piston 2 0682 34 Screw 2 ACZ41783 AC244994 wores 35 O ring Buna N 2 3
23. r Casting Item 8 6 Remove four Tie Rods Item 25 7 Remove Air Tube Item 7 8 Lift upward and remove Cylinder Tube Item 6 Remove Piston and Piston Rod Item 5 10 Remove four Connecting Rods Item 41 with open end wrench 11 To REASSEMBLE REVERSE procedure NOTE Align two holes on the the Cylinder Tube Item 6 with two holes on the Pump Stop Subassembly before tightening Tie Rods Item 25 so that proper seal with O rings is achieved Page Number 7 STANDARD AIRMOTOR WITHOUT PUMP STOP POWER VALVE SUBASSEMBLY Torque to 10 12 ft Ibs Torque to 50 in Ibs After 24 hours Re torque to 50 in 5 Model Torque to MUFFLER CYLINDER TUBE PARTS PILOT BAR SUBASSEMBLY Page Number 8 10 12 Ft Lbs Torque to Using Loctite 242 Blue on threads Assemble Adapter to Piston Rod AIRMOTOR WITHOUT PUMP STOP 4 1 4 Airmotor Only T m A A A sm wA um m wm we re 2 OH OOO oc 8 SNE 2 Page Number 9 STANDARD AIRMOTOR WITH PUMP STOP BN 10 27 A 9 2d 13 Torque to 14 10 12 ft Ibs POWER VALVE SUBASSEMBLY CYLINDER TUBE PARTS NOTE Refer to page 4 for service assembly amp kits Page Number 10 Torque to 50 in Ibs After 24 hours Re torque to 50 in Ibs MUFFLER SUBASSEMBLY 73 24 C
24. rt No 988528 6 Airmotor Item 31 2 Included in 988752 Cylinder Tube Soft Parts 7 Included in AC244093 Gasket Plate with Kit for Part No 988526 4 Airmotor Check Valves Item 90 3 Included in 988751 Soft Parts Kit for Power 8 Included in AC244092 Air Pump Repair Kit Valve Subassembly Item 92 4 Included in 988746 Soft Parts Kit for Pump 9 Included in AC244091 Stop Valve Repair Kit Stop Subassembly Item 91 5 Included in AC273427 Gasket and Air Filter 10 Included in 988750 Power Valve amp Spool Kit Item 89 Bogy Page Number 15 FOR AIRMOTORS WITH PUMP STOP PARTS LIST CONTINUED FROM THE PREVIOUS PAGE Part No Part No 988528 988526 6 Dia 4 1 4 Dia AC273385 AC273386 AC273387 AC273379 AC273396 AC273389 AC34499 AC273393 AC69102 273391 273392 273380 243845 273381 273382 243844 273427 1 AC244093 AC244091 AC244092 2 lt 2 32 Soc Cap Screw asket Nitrile Fiber ntermediate Base asket Nitrile Fiber aminated Labyrinth abyrinth Cover Ring Nitrile 32 x 1 Soc Hd Cap Screw a A 82 83 84 85 ndex Pin Spring Compression Selector Knob N 87 88 Selector Cover Gasket amp Filter Kit Gasket Plate amp Check Valves Stop Valve Repair Kit 92 Air Pump Repair Kit N M 74 XE 76 O7 78 79 80 892 83 894 85 86 87 88 89 90 05
25. s by turning the selector knob to the RUN mode setting immediately after the airmotor has stopped Ifa sudden rush of air escaping is heard the labyrinth is either blocked installed incorrectly Grease or dirt on balls item 81 in labyrinth cover Clean balls and labyrinth cover with solvent Coat with Laminated labyrinth plate item 77 is installed Observe the laminated labyrinth plate and find single hole Stop Valve vent hole in Lower Body Item Unclog vent hole in lower body its Stop valve Item 60 is damaged Check stop valve and replace if worn or Diaphragm seal is damaged worn deformed Replace damaged or worn diaphragm seal or reinstall or improperly installed if good into diaphragm item 58 with twisting action to fully seat in mating hole Inadequate air supply to airmotor See above for checking air supply Ensure that air regulator is set to air pressure at or greater than the minimum recommended air pressure for the airmotor installed Discharge Umbrella Valve Item 63 is damaged Replace both umbrella valves or worn Diaphragm seal is damaged worn deformed or Replace damaged or worn diaphragm seal or reinstall improperly installed if good into diaphragm item 58 with twisting action to fully seat in mating hole Leaking Upper Gasket Item 51 or Lower Replace gaskets items 51 amp 53 Gasket Item 53 Stuck Metering Pump Piston Item 55 Install air pump repair kit replacing
26. t air line and relieve vent pressure when Airmotor sits idle for long periods of time and before servicing A WARNING ALWAYS read and follow the fluid and solvent manufacturer s recommendations regarding the use of protective clothing and equipment WARNING To reduce the risk of serious bodily injury or property damage NEVER exceed the maximum air or fluid working pressure of the lowest rated system component ATTACHING AIRMOTOR TO PUMPTUBE 1 Tightly attach the tie rods Item 41 to the Airmotor lower casting Use short threaded end of tie rods 2 Mount Airmotor on top of pump tube outlet and tightly connect pump tube coupling nut to Airmotor Piston Rod Item 5 3 Hand tighten tie rods to the pump tube with four nuts Item 42 supplied with Airmotor 4 Connect air supply and slowly cycle pump several times using only enough air pressure to operate pump without stalling 5 STOP pump on UP stroke and tighten four nuts to securely fasten Airmotor to pump tube Pilot Bar Subassembly 1 Remove four Screws Item 23 two on each end with 3 16 hex wrench and pull out Pilot Bar Subassembly 2 Remove two Screws Item 39 with 7 64 hex wrench and lift out Valve Body Item 17 3 Remove four Screws Item 40 two on each side of Pilot Bar and lift off Upper Bracket Item 31 and Lower Bracket Item 32 4 Remove Air Signal Valves Item 20 5 ToREASSEMBLE REVERSE procedure Cylinder Tube and Muffler
27. tarting the pump the pump may be cautiously restarted and observed for any indications of a problem before resuming normal operation Resetting the Pump Stop after Tripping 2 Turn off the air supply to the air motor Press the Flush Reset Button located on the right side of the Relay Valve item 17 with a screwdriver or other suitable ob ject See Illustration 3 below until the air motor shifts and the Indicator pin in item 48 retracts into the Pump Stop Hold the reset button until all air has been vent ed from the air motor On large air mo tors this may take several seconds Oth erwise wait for about 2 minutes until all air has been vented before attempting a restart Turn on air supply and the air motor will restart Flush Reset Button Illustration 3 If the cause of the Pump Stop trip is cavi tation or a broken fluid line the Pump Stop may trip again very quickly When in the process of setting up a sys tem and determining the speed of the pump pump tube system use the RUN set ting to prevent unnecessary tripping of the Pump Stop while set up is in progress or when trouble shooting the system Be sure to reactivate the Pump Stop by re setting to the desired run setting before leaving the pump system unattended Vent Hole Illustration 4 Rear View of Pump Stop Page Number 17 Airmotor is not operating air is coming from exhaust
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