EQUIPMENT
Operation Manual AC988557
Loctite® Airmotors
Part Numbers
988526 (4-1/4” Airmotor)
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.
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 chemicals 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.
Copyright 2004
Printed in U.S.A.
JULY - 2004
Form 403504
FOR STANDARD AIRMOTOR WITHOUT PUMP STOP
SERVICE ASSEMBLIES & 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.
6. Power Valve Subassembly
P/N AC244806 (6” Airmotor)
P/N AC244808 (4-1/4” Airmotor)
1. Pilot Bar Subassembly
P/N 988747
7. Soft Parts Kit P/N 988751 for repair of Power Valve
Subassemblies listed above.
8. Power Valve Spool & Body P/N 988750
2. Soft Parts Kit P/N 988746 for repair of Pilot Bar
Subassemblies listed above. (Includes all necessary
“O”-rings.)
3. Relay Valve. P/N 988748
4. Air Signal Valve P/N 988749
5. Cylinder Tube Soft Parts Kit
( Includes all “O”-rings, 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 & 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
244091 Item 91 (includes items
57, 58, 59, 60, 61)
12.Cylinder Tube Soft Parts Kit
(Includes “O”-rings, piston seal,
etc.) P/N 988753 (6" Airmotor)
P/N 988752 (4-1/4"Airmotor)
1. Pump Stop Subassembly
P/N 988545
13.Power Valve Subassembly
P/N AC244806 (6" Airmotor)
P/N AC244808 (4-1/4" Airmotor)
8. Air Pump Repair Kit P/N AC244092
Item 92 (includes items 55, 56, 62,
63, 64, 65)
14.Soft Parts Kit P/N 988751 for repair
of Power Valve Subassemblies
listed above.
9. Bleed Assembly P/N AC273428
Item 67 (includes items 73 through
88)
2. Soft Parts Kit P/N 988746 for repair
of Pump Stop Subassembly. (See
Parts List for contents.)
15.Power Valve Spool & 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 & 53)
5. Air Signal Valve P/N 988749, Item
20
11. Gasket Plate with Check Valves
Item 90 P/N AC244093 (Items 52 &
63)
89
40
53
51
50
6. Trip Indicator P/N AC243852 Item
48
63
52
63
90
Page Number - 4
FOR STANDARD AIRMOTOR
Disconnect air line and relieve (vent) pressure when Airmotor sits
idle for long periods of time and before servicing.
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.
ALWAYS read and follow the fluid and solvent manufacturer’s
recommendations regarding the use of protective clothing and
equipment.
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 for non-
restrictive air flow.
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.
If quick disconnect coupling should be used, install supplied coupler
to insure proper airmotor operation.
ATTACHING AIRMOTOR TO PUMPTUBE
1
Tightly attach the tie rods (ltem 41) to the Airmotor lower
casting. Use short threaded end of tie rods.
NOTE: Whenever flammable materials are pumped, ground Airmotor
according to Local Codes.
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.
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
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).
Always disconnect air supply to Airmotor and relieve pressure
before checking, servicing, or repairing any part of Airmotor
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. To REASSEMBLE, REVERSE procedure.
TOOLS REQUIRED
1. 7/64 (.109) Hex Wrench
Cylinder Tube and Muffler
1. Remove Pilot Bar Subassembly (See previous instructions).
2. Remove two Screws (Item 30) with 3/16” hex wrench and re-
move muffler subassembly.
2. 5/32 (.156) Hex Wrench
3. 3/16 (.189) Hex Wrench
4. 3/4 (.750) Open End Wrench (for 6” Airmotor)
5. 1/2” (.500) Open End Wrench (for 4-1/4” Airmotor)
6. Pliers
3. Remove Gasket (Items 28).
4. Remove four Nuts (Item 26) with open end wrench.
5. Lift upward and remove Upper Casting (Item 8).
6. Remove four Tie Rods (Item 25).
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.
7. Remove Air Tube (Item 7).
8. Lift upward and remove Cylinder Tube (Item 6).
9. Remove Piston and Piston Rod (Item 5).
10. Remove four Connecting Rods (Item 41) with open end wrench.
11. To REASSEMBLE, REVERSE procedure.
Power Valve
1. Remove four screws (Items 27 & 34) with 3/16” hex wrench (2
on each side).
2. Remove End Caps (Items 10 & 14).
3. Push out Valve Spool (Item 13).
4. Remove Spool Bumpers (ltem 9) (One from each end).
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).
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.
7. Remove Gasket (Item 15) to complete valve disassembly.
8. To REASSEMBLE, REVERSE procedure.
Page Number - 5
FOR AIRMOTOR WITH PUMP STOP
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.
ATTACHING AIRMOTOR TO
PUMPTUBE
DO NOT OPERATE Airmotor in excess of
recommended pressure range.
1. Tightly attach the tie rods(ltem 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.
Disconnect air line and relieve (vent)
pressure when Airmotor sits idle for long
periods of time and before servicing.
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.
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.
If quick disconnect coupling should be
used, install supplied coupler to insure
proper airmotor operation.
11. To re-assemble, reverse the disassem-
bly procedure with the following
precautions
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).
SERVICEANDDISASSEMBLY
PROCEDURE
a. The upper and lower gaskets (items
51 & 53) should be coated with a
film of light oil (SAE 10) before
assembly.
7. Remove Gasket (Item 15) to complete
valve disassembly.
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.
8. To 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 Caps
(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 & 60).
Tools Required
1. 7/64" (.109) Allen Wrench
2. 5/32" (.156) Allen Wrench
3. 3/16" (.189) Allen Wrench
4. 1/8" (.125) Allen Wrench
5. 9/64" (.1406) Allen wrench
6. 3/4" (.750) Open End Wrench (for 6" Air-
motor)
7. #1 Phillips screwdriver
8. 1/2” (.500) Open End Wrench
9. 1/2" (.500) Box End Wrench
10. Pliers
11. 0-100 in. lb. Torque Wrench
12. 0 - 75 Ft. lb. Torque Wrench.
d. When installing the pump sleeve,
(item 56) into the lower body, (item
54) the sleeve should be placed into
the lower body as shown in
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.
Illustration on Page 12. When
properly installed the molded pin
protruding from the pump sleeve will
fit into 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.
Power Valve
1. Remove four screws (Items 27 & 34)
with 3/16” hex wrench (2 on each
side).
2. Remove End Caps (Items 10 & 14).
3. Push out Valve Spool (Item 13).
4. Remove Spool Bumpers (Item 9) (One
from each end).
10. Remove Trip Indicator (Item 48).
Page Number - 6
Cylinder Tube and Muffler
LabyrinthSub-Assembly
DisassemblyProcedure:
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.
1. 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 Upper 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).
9. Remove Piston and Piston Rod (Item 5).
10. Remove four Connecting Rods (Item 41)
with open end wrench.
11. To REASSEMBLE, REVERSE
procedure.
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.
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.
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 basically 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-lbs.
5. When installing the labyrinth sub-
assembly onto the Pump Stop assembly
use four screws (item 80) and tighten
to 12 in-lbs.
Page Number - 7
STANDARD AIRMOTOR WITHOUT PUMP STOP
30
29
Model
988526 11 Ft. Lbs.
988528 26 Ft. Lbs.
Torque to
28
45
43
Page Number - 8
AIRMOTOR WITHOUT PUMP STOP
Page Number - 9
STANDARD AIRMOTOR WITH PUMP STOP
Model
Torque to
988526 11 Ft. Lbs.
988528 26 Ft. Lbs.
30
29
28
45
43
* 4-1/4" Airmotor only
NOTE: Refer to page 4 for service assembly & kits
Page Number - 10
39
92
3
24
73
75
74
No
sho
on
Item 67 Detail
Assembly
Page Number - 11
Note holes at 9 & 6 o'clock positions
40
56
40
54
Molded pin on pump sleeve. Position to
about 7 O'Clock position as shown.
Page Number - 12
AIRMOTOR WITH PUMP STOP
Page Number - 13
PARTS LIST - AIRMOTOR WITHOUT PUMP STOP
Item Description
Qty. Part No. 988528 Part No. 988526
No.
(6” Dia.)
(Note #1)
AC241732
(Note #1)
(Note #1)
AC241741
AC241745
AC241748
AC241751
(Note #4)
AC241755
(Note #4)
(Note #5)
(Note #5)
AC241760
(Note #4)
(Note #4)
AC242787
(Note #3)
(Note #3)
AC241768
(Note #1)
AC241774
AC50526
AC241778
AC241779
AC51007
AC244995
AC241024
AC84722
AC50553
AC241784
AC241785
—
(4-1/4” Dia.)
(Note #2)
AC241733
(Note #2)
(Note #2)
AC241742
AC241746
AC241749
AC241752
(Note #4)
AC241755
(Note #4)
(Note #5)
(Note #5)
AC241761
(Note #4)
(Note #4)
AC242787
(Note #3)
(Note #3)
AC241768
—
AC241775
AC50526
AC241778
AC241767
AC51001
AC244995
AC241024
AC84722
AC50553
AC241784
AC241785
(Note #2)
AC244994
(Note #3)
AC241789
AC244975
AC655008
AC50816
AC50823
AC241023
AC236023
AC273507
AC653112
AC67062
1
2
3
4
5
6
7
8
9
U-Cup (Buna-N)
Rod Bearing
Seal, Cylinder (Buna-N)
O-ring (Buna-N)
Piston Rod Assembly
Cylinder Tube
Air Tube
Upper Casting
Bumper, Valve
1
1
2
2
1
1
1
1
2
1
2
1
1
1
1
2
1
3
3
2
1
1
4
1
4
4
2
1
1
2
1
1
2
2
2
1
4
1
2
4
4
4
1
1
1
10 Cap, Valve
11 O-ring (Buna-N)
12 Body, Valve
13 Spool, Valve
14 Cap, Valve
15 Gasket
16 O-ring (Buna-N)
17 Relay Valve
18 O-ring (Buna-N)
19 O-ring (Buna-N)
20 Air Signal Valve
21 O-ring Piston(Buna-N)
22 Lower Casting
23 Screw (1/4-20 x 7/8”)
24 Pilot Bar
25 Tie Rod
26 Nut
27 Screw
28 Gasket
29 Muffler Adapter
30 Screw (1/4-20 x 1-1/4")
31 Bracket, Upper
32 Bracket, Lower
33 Seal, Piston
34 Screw
35 O-ring (Buna-N)
36 Adapter
37 Screw (1/4-20 x 2¼")
38 Coupler
39 Screw (6-32)
40 Screw (1/4-20)
41 Tie Rod
42 Nut (1/2-20)
43 Muffler
Parts List Notes:
AC241783
(Note #3)
—
NOTES:
1. Included in 988753 Cylinder Tube Soft Parts
Kit for Part No. 988528 (6” Airmotor).
2. included in 988752 Cylinder Tube Soft Parts
Kit for Part No. 988526 (4-1/4” Airmotor).
3. Included in 988746 Soft Parts Kit for Pilot Bar
Subassembly.
4. Incuded in 988751 Soft Parts kit for Power
Valve Assembly.
5. Included in 988750 Power Valve Spool &
Body.
AC244975
AC655012
AC50816
AC50823
AC241023
AC236023
AC273507
AC653112
AC67062
44 Nipple
45 Elbow
46 Unused
47 Unused
48 O-ring (Buna-N)
49 O-ring (Buna-N)
2
4
(Note #3)
(Note #3)
(Note #3)
(Note #3)
Page Number - 14
PARTS LIST FOR AIRMOTORS WITH PUMP STOP
Part No.
Qty. 988528
(6" Dia.)
Part No.
988526
(4¼" Dia)
Part No.
988528
(6" Dia.)
(Note #4)
------
AC244975
AC655012
AC50816
(Note #5)
AC241023
AC236203
AC273507
AC653112
AC67062
Part No.
988526
Item
No.
Item
No.
Qty
.
Description
Description
(4¼" Dia)
(Note #4)
AC241789
AC244975
AC655008
AC50816
(Note #5)
AC241023
AC236203
AC273507
AC653112
AC67062
1
2
3
4
5
6
7
8
9
U-Cup (Buna-N)
Rod Bearing
Seal, Cylinder (Buna-N)
O-ring (Buna-N)
Piston Rod Assembly
Cylinder Tube
Air Tube
Upper Casting
Bumper, Valve
1
1
2
2
1
1
1
1
2
1
2
1
1
1
1
2
1
3
1
2
1
1
4
4
4
4
2
1
1
2
2
4
2
2
(Note #1) (Note #2) 35 O-ring (Buna-N)
AC241732 AC241733 36 Adapter
(Note #1) (Note #2) 37 Screw (¼-20 x2¼")
(Note #1) (Note #2) 38 Coupler
2
1
4
1
2
2
4
4
1
1
1
AC241741 AC241742 39 Screw
AC241745 AC241746 40 Air Filter
AC241748 AC241749 41 Tie Rod
AC241751 AC241752 42 Nut (½-20)
(Note #3) (Note #3) 43 Muffler
AC241755 AC241755 44 Nipple
(Note #3) (Note #3) 45 Elbow
(Note #10) (Note #10) 46 Not Used
(Note #10) (Note #10) 47 Not Used
AC241760 AC241761 48 Trip Indicator
(Note #3) (Note #3) 49 O-ring (Buna-N)
(Note #3) (Note #3) 50 Upper Body
AC242787 AC242787 51 Upper Gasket (Nitrile)
(Note #4) (Note #4) 52 Gasket Plate
(Note #4) (Note #4) 53 Lower Gasket (Nitrile)
AC241768 AC241768 54 Lower Body
10 Cap, Valve
11 O-ring (Buna-N)
12 Body, Valve
13 Spool, Valve
14 Cap, Valve
15 Gasket
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
AC243852
(Note #4)
AC243855
(Note #5)
(Note #7)
(Note #5)
N/A
(Note #8)
(Note #8)
(Note #9)
(Note #9)
(Note #9)
(Note #9)
(Note #9)
(Note #8)
AC243852
(Note #4)
AC243855
(Note #5)
(Note #7)
(Note #5)
N/A
(Note #8)
(Note #8)
(Note #9)
(Note #9)
(Note #9)
(Note #9)
(Note #9)
(Note #8)
16 O-ring (Buna-N)
17 RelayValve
18 O-ring (Buna-N)
19 O-ring (Buna-N)
20 Air Signal Valve
21 O-ring Piston(Buna-N)
22 Lower Casting
23 Screw (¼-20 x1½")
24 Screw (¼-20 x7/8")
25 Tie Rod
26 Nut
27 Screw
28 Gasket
29 Muffler Adapter
30 Screw (1/4-20 x1-1/4")
31 Signal Valve Cap Kit
32 Screw (8-32 x5/8)
33 Seal, Piston
34 Screw
(Note #1)
------
55 Piston
AC241774 AC241775 56 Pump Sleeve
AC50051 AC50051 57 Diaphragm Retainer
AC50850 AC50850 58 Diaphragm
AC241779 AC241767 59 Spring
AC51007 AC51001 60 Stop Valve Assembly
AC244995 AC244995 61 Diaphragm Seal
AC241024 AC241024 62 O-ring (Buna-N)
AC84722 AC84722 63 Umbrella Seal (Nitrile)
AC50553 AC50553 64 Quad Ring (Buna-N)
AC243853 AC243853 65 Quad Ring (Buna-N)
(Note #6) (Note #6) 66 Spring Pin
(Note #7 & 8) (Note #7 & 8)
(Note #8)
(Note #8)
AC243614
AC243854
(Note #8)
(Note #8)
AC243614
AC243854
------
(Note #2) 67 Bleed Assembly
AC241783 AC244994
NOTES: 1. Included in 988753 Cylinder Tube Soft Parts
Kit for Part No. 988528 (6" Airmotor).
2. Included in 988752 Cylinder Tube Soft Parts
Kit for Part No. 988526 (4¼" Airmotor).
3. Included in 988751 Soft Parts Kit for Power
Valve Subassembly.
6. Included in AC243853 Signal Valve Cap Kit
Item 31.
7. Included in AC244093 Gasket Plate with
Check Valves Item 90.
8. Included in AC244092 Air Pump Repair Kit
Item 92.
4. Included in 988746 Soft Parts Kit for Pump
Stop Subassembly.
9. Included in AC244091 Stop Valve Repair Kit
Item 91.
5. Included in AC273427 Gasket and Air Filter
Kit Item 89.
10. Included in 988750 Power Valve & Spool
Body.
Page Number - 15
FOR AIRMOTORS WITH PUMP STOP
PARTS LIST (CONTINUED FROM THE PREVIOUS PAGE)
Part No.
Part No.
Item No. Description
Qty.
988528
988526
(6" Dia.) (4-1/4" Dia)
AC273385 AC273385
AC273386 AC273386
AC273387 AC273387
AC273379 AC273379
AC273396 AC273396
AC273389 AC273389
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
8-32 Soc. Hd. Cap Screw
6
1
1
1
1
1
7
4
7
1
1
1
2
1
1
1
1
1
1
1
Gasket (Nitrile/Fiber)
Intermediate Base
Gasket (Nitrile/Fiber)
Laminated Labyrinth
Labyrinth Cover
O-Ring (Nitrile)
8-32 x 1 Soc. Hd. Cap Screw
Ball
Index Pin
Spring Compression
Selector Knob
Washer,Spring
Selector Bolt
AC34499
AC273393 AC273393
AC69102 AC69102
AC34499
AC273391 AC273391
AC273392 AC273392
AC273380 AC273380
AC243845 AC243845
AC273381 AC273381
AC273382 AC273382
AC243844 AC243844
AC273427 AC273427
AC244093 AC244093
AC244091 AC244091
AC244092 AC244092
Selector Cover
Screw
Gasket & Filter Kit
Gasket Plate & Check Valves
Stop Valve Repair Kit
Air Pump Repair Kit
Page Number - 16
pump by counting the number of strokes
the pump makes per minute.
Setting the Pump Stop Trip
Speed
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.
Illustration2
fluid levels, broken hose or fitting connec-
tions before restarting. If a cause cannot
be determined without starting the pump the
pump may be cautiously restarted and
observed for any indications of a problem
before resuming normal operation.
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.
Speed
Setting
Legend
Resetting the Pump Stop after
Tripping
Speed
Setting
Dial
1. Turn off the air supply to the air motor.
2. 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.
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.
Illustration1
Speed Settings:
R
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.
A
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 exceeded. 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.
B
C
D
E
F
3. Turn on air supply and the air motor will
restart.
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.
Illustration3
4. If the cause of the Pump Stop trip is cavi-
tation or a broken fluid line the Pump Stop
may trip again very quickly.
Broken Hose or Fitting: will cause a loss
in fluid pressure allowing the pump to run
faster than normal.
5. 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.
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.
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
of a pump/pump tube combination.
Precision control of the pump
Increase in Demand: Fluid demand may
be greater than expected.
operating speed is beyond the scope
of this device.
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)
1. Remove the selector cover (item 87) by
removing screw (item 88) to gain access
to the selector knob (item 84).
2. 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).
Vent Hole
Before resetting, the cause of the OVER-
RUN should be determined if possible
before restarting the pump. Check for low
3. With the pump and air motor operating
normally, determine the speed of the
Illustration4
Rear View of Pump Stop
Page Number - 17
PROBLEM
Airmotor is not operating, air is
coming from exhaust.
POSSIBLE CAUSE
Inadequate air supply to airmotor.
SOLUTION
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.
Erratic or accelerated operation
with short stroking. Airmotor
hesitates on up or down stroke.
Dirty or damaged Relay Valve (Item 17)
or Air Signal Valve (Item 20) or stop valve
assembly (Item 60).
Check valves and clean if necessary.
Replace any damaged seals or worn parts.
Pump Cavitation
Check Fluid Level. Ensure that pump inlet is not blocked
or restricted or is large enough to handle flow into
pump inlet.
Pump Stop trips off even though
airmotor is operating below set
trip speed. (Trips after three or
more strokes.)
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 (in quiet locations)
by turning the selector knob to the RUN mode setting
immediately after the airmotor has stopped. If a 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
(Item 78).
verylight film of light grease to hole balls in cover.
Replace Diaphragm.
Replace Upper & Lower Gaskets (Items 51 & 53).
Replace Quad Ring.
Observe the laminated labyrinth plate and find single hole
on item 76 and align with hole on Item 75.
Unclog vent hole in lower body.
Pump Stop trips even though
airmotor is operating below set
trip speed (within three
strokes).
Leaking Diaphragm (Item 58).
Leaking Upper Gasket (Item 51).
Upper Piston Quad Ring (Item 64) is leaking.
Laminated labyrinth plate (item 77) is installed
incorrectly.
Pump Stop trips at proper speed Stop Valve vent hole in Lower Body(Item
(as indicated by the sound of air
surging into the diaphragm
chamber), but airmotor does not
stop, indicator pin does not
pop out.
54) is clogged or blocked. (See Illustration 7)
Stop valve (Item 60) is damaged.
Check stop valve and replace if worn or
damaged.
Replace damaged or worn diaphragm seal,or reinstall
if good into diaphragm (item 58) with twisting action
to fully seat in mating hole.
Diaphragm seal is damaged, worn, deformed
or improperly installed.
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.
Pump Stop will not trip even
though airmotor has been
running above the trip speed for
more than 1 minute.
Discharge Umbrella Valve (Item 63) is damaged
or worn.
Diaphragm seal is damaged, worn deformed or
improperly installed.
Replace both umbrella valves.
Replace damaged or worn diaphragm seal, or reinstall
if good into diaphragm (item 58) with twisting action
to fully seat in mating hole.
Leaking Upper Gasket (Item 51) or Lower
Gasket (Item 53).
Replace gaskets (items 51 & 53)
Stuck Metering Pump Piston (Item 55).
Inlet Air Filter (Item 40) is completely or
partially clogged.
Install air pump repair kit, replacing items 55, 56, 63, 64 & 65.
Clean or replace inlet air filter.
Page Number - 18
P/N 988552
LOW LEVEL MICROSWITCH KIT
INSTALLATION INSTRUCTIONS
1) Remove Trip Indicator Plug from Pump Stop Install the
Switch Bracket (in position shown) on Pump Stop and
secure by reinstalling Trip Indicator Plug.
2) Using the two mounting screws, washers and nuts,
assemble the 69360 Limit Switch (in up position as
shown) to Switch Bracket loosely.
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.
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
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
BYACCIDENT, OR IF THE SYSTEM WAS USED TO DISPENSEANY LIQUID MATERIAL OTHER THAN HENKEL PRODUCTS.
EXCEPT FOR THE EXPRESS WARRANTY CONTAINED IN THIS SECTION, HENKEL MAKES NO WARRANTY OF ANY KIND
WHATSOEVER, EXPRESS OR IMPLIED, WITH RESPECT TO THE PRODUCTS.
ALL WARRANTIES OF MERCHANTABILITY, FITNESS FORAPARTICULAR PURPOSE, AND OTHER WARRANTIES OF WHAT-
EVER KIND (INCLUDING AGAINST PATENT OR TRADEMARK INFRINGEMENT)ARE HEREBY DISCLAIMED BY HENKELAND
WAIVED BY THE PURCHASER.
THIS SECTION SETS FORTH EXCLUSIVELYALL OF LIABILITY FOR HENKELTO 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 PROFITSAND SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, WHETHER CAUSED
BY NEGLIGENCE FROM HENKEL OR OTHERWISE.
Henkel Corporation
1001 Trout Brook Crossing
Rocky Hill, CT 06067-3910
Henkel Canada Corporation
2225 Meadowpine Boulevard
Mississauga, Ontario L5N 7P2
Henkel Capital S.A. de C.V.
Calzada de la Viga s/n Fracc. Los Laureles
Loc. Tulpetlac, C.P. 55090
Ecatepac de Morelos Edo. de México
Henkel Automotive
Henkel Ltda.
Technology Center
2455 Featherstone Road
Auburn Hills, Michigan 48326
Rua Karl Huller, 136 - Jd.
Canhema 09941-410
Diadema/SP, Brazil
Loctite is a registered trademark of Henkel Corporation, U.S.A . © Copyright 2004. Henkel Corporation. All rights reserved. Data
in this operation manual is subject to change without notice.
Page Number - 20
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