Loctite Ac988557 User Manual

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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