Val-Tex Easy Lube 40-70 User manual

40-70
OPERATINGMANUAL
Contents:
-Catalog Sheet
-40-70 Requirements
-Before Operating the 40-70
-Operating the 40-70
-Periodic Maintenance
-Instructions for use of 40-70 Pail Adapter
-Service Instructions and Parts List for High Pressure Pump Model 8540-A1
-Service Instructions and Parts List for Air Motor Model 324400-5
-Service Instructions and Parts List for Pump Tube 331378
-Service Instructions & Parts List for Volume Control Valve #6438
-Drawing and Parts List for Canister and Dolly
-Additional parts listing

Val-Tex Air Operated
Lubrication Equipment
Val-Tex Air Operated
Lubrication Equipment
10600 FALLSTONE ROAD HOUSTON, TEXAS 77099-4390 ORDER 1-800-627-9771 PHONE [phone] FAX [phone]
Delivery: 1/16 ounc p r strok
PSI Rating: 10,000
Self Priming: Spring load d follow r plat
Air Pressure Required: 125 to 185 PSI
Typical Pressure Delivered through a 10 foot hose
at 150 PSI:
Lube Sealant - 8,000 PSI
Valve Flush -
CF Required: 6
Gauge: Includ d
Internal Relief Valve: No
For Use With: 5 qt. / 10 lb. can
Dimensions: 25" high X 10" width
Approximate Weight: 50 lbs. / 22.68 kg.
For Use With: 5 qt. / 10 lb. can
Dimensions: 43" high X 18" wid X 28" long
Approximate Weight: 76 lbs. / 34.47 kg.
For Use With: 5 gal. / 40 lb. pail
Dimensions: 37" high X 19" wid X 24" long
Approximate Weight: 78 lbs. / 35.38 kg.
These powerful, portable,
NOTE:
air op rat d lubrication guns
hav a 70:1 ratio air motor to quickly pump bulk lub
s alants and Valv Flush. A sp cial follow r plat and
spring assur s positiv priming. All units com quipp d
with a 15,000 PSI gaug , Gaug Guard, dual swiv ls,
control handl , 10 foot, 3/8 inch I.D. high pr ssur gr as
hos and whip nd hos with giant buttonh ad coupl r.
Fully automat d with no manual activation r quir d.
Wh n pumping Valv Flush, r mov th follow r
plat .
"L'il Greaser" - odel 5-70
"Easy Lube" - odel 10-70
"Easy Lube" - odel 40-70
Th carrying handl mak s this compact, portabl gun id al for tight plac s,
ov rh ad lubrication, and asy transporting around th fi ld. Th nclos d s alant
canist r k ps dirt and for ign mat rial out.
Caddy typ cart with larg rubb r tir d wh ls assur s asy man uv rability. Th
nclos d s alant canist r k ps dirt and for ign mat rial out.
A practical gun for s rvicing a larg numb r of valv s. Th r v rsibl pail adapt r
provid s unint rrupt d flow. Th swing typ dolly mount d on rubb r tir d wh ls
k ps th contain r upright at all tim s. Th nclos d s alant canist r k ps dirt and
for ign mat rial out. H avy duty latch s k p th lid s cur .
"Quality That Pays For Itself"
8,000 PSI
16
10600 FALLSTONE ROAD • HOUSTON, TEXAS 77099-4390 • ORDER 1-800-627-9771 • PHONE [phone] • FAX [phone] • WWW.VALTEX.COM
REV. 4/01

The Val-Tex 40-70 comes equipped with a modified 8540-A1 High Pressure Pump. The service
instructions enclosed provide a general guide as to safety requirements, disassembly,
reassembly and parts. Please consult Val-Tex when reordering replacement parts. Standard
Alemite parts may not apply.
40-70 Requirements
To obtain 8000 PSI output requires 150 PSI of air at 6 CFM.
Air Regulator, moisture separator and oiler (not included) are recommended on the air supply line
to prolong the life of the pump.
Before Operating the 40-70
1. Connect lube sealant hose assembly to the motor. Check all threaded connections to ensure
the hose assembly is properly tightened.
2. To Pump Lube Sealant: (NOTE: See the instructions for use of the 40-70 pail adapter prior to
inserting the pail.)
A. Open the pail of lube sealant and place it in the bottom of the canister.
B. Insert the follower plate into the lube sealant can.
C. Clamp the canister lid down by tightening down the knurled nuts on the three thumb
screws.
D. Secure the latches by engaging them into the strike.
3. To Pump Valve Flush: (NOTE: See the instructions for use of the 40-70 pail adapter prior to
inserting the pail.)
A. Open the pail of Valve Flush and place it in the bottom of the canister.
B. Remove the follower plate from the pump tube before use.
1) Remove the snap ring that secures the follower plate to the bottom of the pump
tube.
2) Remove the follower plate from the pump tube.
C. Insert the pump tube into the Valve Flush can.
D. Clamp the canister lid down by tightening down the knurled nuts on the three thumb
screws.
E. Secure the latches by engaging them into the strike.
4. Connect the air hose to the pump

Operating the 40-70
1. Depressing the control handle (6438) will activate the pump. Continue until material flows
from the end of the hose. *
2. Connect to the fitting and begin injecting into the valve.
3. After the pail is approximately half empty, please refer to the "Instructions for use of 40-70
Pail Adapter."
*Dispose of any expelled material properly.
Periodic Maintenance
1. Refer to service instructions for model 8540-A1.

FOR VAL-TEX 40-70 ONLY
POSITION WHEN FULL POSITION WHEN HALF EMPTY
10600 Fallstone Rd. • Houston, TX 77099 • Phone: [phone] or 800-627-9771 • www.valtex.com • [e-mail]
1. When loading a full pail of Val-Tex lube sealant the pail should fit
down inside the centering ring and rest on the bottom of the
pump canister.
2. When the pail is about half empty it should be removed from the
canister and the centering ring turned over so that the pail is
sitting elevated 3 inches off the bottom of the canister. Valve
Flush pails should always be loaded in the half empty position
without a follower plate.

Service Guide
SER 8540-A1
8540-A1
8541-5
Alemite Corporation
PO Box 473515, Charlotte, North Carolina 28247-3515
www.alemite.com
Copyright
©
1998 by Alemite Corporation
This document contains confidential information that is the property of Alemite Corporation
397987
and is not to be copied, used, or disclosed to others without express written permission.
Revision (7-98)
Air
Inlet
Figure 1 Pump Models 8540-A1 and 8541-5
Model 8541-5 Shown
Description
The major components of high-pressure pump assembly
models 8540-A1 and 8541-5 consist of a(n):
• air-operated motor
• lubricant pressure controller (pressurtrol)
• double-acting reciprocating pump tube
• cover assembly and follower plate
• control valve, z-swivel, hose, & dolly (Model 8541-5)
The pressurtrol minimizes material pressure drop that
occurs when the pump cycles. Refer to SER 319800-1 for
details.
Pump Assembly
The high-pressure (70:1 ratio) pump assembly included
with each model is designed to deliver a range of greases
[up to NLGI # 3] and operates directly from an original
120-pound container.
Models 8540-A1 and 8541-5
Model 8540-A1 is stationary. It contains a cover and
follower plate. Model 8541-5 is portable and includes a
dolly, control valve, z-swivel, and delivery hose.
Specifications
Air Motor
Pump Tube
Piston Diameter x Stroke Air Inlet Max. Air Pressure *
Inches Centimeters psi Bars
3 x 1-5/8 7.6 x 4.1 1/4 " NPTF (f) 200 13.8
* With pressurtrol, [100 psi (6.9 Bars) without pressurtrol]
For information on the air motor, refer to SER 324400-5
Material
Outlet
Max. Material
Pressure Max. Delivery/
Minute
(Approximate)* Displacement
per Cycle
psi Bars Ounces Grams in
3
cm
3
3/8 " NPTF (f) 7500 517 32 909 0.277 4.54
* For detailed information, refer to Service Guide SER 8540-B
Table 1 Pump Assembly Specifications
High-Pressure Pump (Stationary and Portable)
Pump
Model Cover and
Follower Control Valve,
Z-Swivel, Hose,
and Dolly
Width x Height
(including container)
Inches Cm
8540-A1 15 x 39-3/4 38 x 101
8541-5 20-1/4 x 43-1/4 51 x 109

SER 8540-A1 High-Pressure Pump (Stationary and Portable)
Revision (7-98) 2 Alemite Corporation
1
To Item
Number 5
7
6
11
14
To Item
Number 3
Apply
Thread Sealant
Here
Apply
Thread Sealant
Here
Apply
Thread Sealant
Here
4
5
2
2
8
9
10 12
13
15
3
NOTE: Coupler points upward
on Model 8540-A1
Apply
Loctite 222
Here
Figure 2 High-Pressure Lubricant Pump (Stationary and Portable) Models 8540-A1 and 8541-5 - Exploded View

High-Pressure Pump (Stationary and Portable) SER 8540-A1
Alemite Corporation 3 Revision (7-98)
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
18540-B Pump Assembly, High-Pressure 1 See SER
8540-B
6320-3 (4)
2 317875-7 Hose Assembly, Material 1
Model 8541-5
8540-B (1)
3 44734 Adapter, 3/8 “ NPTF (m) x 1/2 " -27 1 17804 (8)
4 6320-3 Valve Assembly, Control 1 See SER 6320-3 44734 (3)
5 B52752 Z-Swivel Assembly, High-Pressure 1 See Figure 3 48018 (11)
6 315943 Bushing 1 B52752 (5)
7 338371 Cover Assembly 1 77009 (12)
8 Washer, 1/4 " 3
Included w/ 338371
77786 (10)
9 Washer, Lock, 1/4 " 3 170561 (13)
10 Capscrew, 1/4 " -20 x 1/2 " 3 172207-1 (9)
11 48018 Screw, Thumb, 1/4 " -28 x 1-1/8 " 3 315953 (6)
12 Washer, Internal Tooth Lock, 1/4 " 1 316315-5 (15)
13 Screw, 1/4 " -20 x 5/16 " 1 317875-7 (2)
14 338802 Plate, Follower 1 320998-B4 (7)
15 316315-5 Dolly Assembly 1 Model 8541-5 See SER 316315-5
338802 (14)
Legend :
Part numbers left blank (or in italics ) are not available separately
Assembly
NOTE : Refer to Figure 2 for component
identification on all assembly procedures.
CAUTION
Select a clean environment for all assembly proce-
dures. Prevent contamination from foreign mate-
rial. Damage to components can occur.
Pump Assembly and Cover
IMPORTANT: Make sure to remove the pro-
tective cover from the inlet of Pump Assem-
bly ( 1 ).
1. Install Pump Assembly ( 1 ) into Cover Assembly ( 7 ).
2. Secure the Pump Assembly to the Cover with
Washers ( 8 ), Lock Washers ( 9 ), and Capscrews ( 10 ).
• Tighten the Capscrews securely.
Cover Assembly and Follower Plate
3. Place Follower Plate ( 14 ) onto the top of the product.
• With a wobbling motion, eliminate any air that may
be trapped underneath the Follower Plate. Force the
product through the hole in the center of the Plate.
4. Guide the pump tube into the Follower Plate and fit the
Cover onto the container.
5. Secure the Cover to the container with Thumb
Screws ( 11 ).
NOTE : On model 8541-5, secure the con-
tainer to Dolly ( 15 ). Refer to SER 316315-5
for details.

SER 8540-A1 High-Pressure Pump (Stationary and Portable)
Revision (7-98) 4 Alemite Corporation
Rubber
Leather
To Control Valve
a
b
c
d
e
f
b
c
d
e
f
e
b
c
d
g
To Material Hose
Control Valve and Material Hose
NOTE : The following procedures are
applicable to pump model 8541-5.
IMPORTANT: Do not apply thread
sealant to the first two (2) threads of
any connection. Contamination can
occur.
WARNING
Do not alter the design of the pump.
Never install additional components to the
outlet of the pressurtrol.
Personal injury can occur.
6. Screw the 3/8 “ NPTF end of Adapter ( 3 ) [with
thread sealant] into the adapter at the outlet of
the air motor.
• Tighten the Adapter securely.
7. Screw either end of Material Hose ( 2 ) into
the Adapter [with thread sealant].
• Tighten securely.
8. Screw the 1/2 " -27 end of Z-Swivel ( 5 ) [with
thread sealant] into the Material Hose.
• See Figure 3 .
• Tighten securely.
9. Screw the opposite end of the Z-Swivel [with
thread sealant] into Control Valve ( 4 ).
• Tighten securely.
10. Test/Prime the Pump assembly.
• Refer to Service Guide SER 8540-B for
details.
Item
No. Part No. Description Notes Qty
a Adapter, Swivel, 1/4 " NPTF (m) 1
b Ring, Support, Male 3
c V-Packing (Rubber) 6
d V-Packing (Leather) 3
e Ring, Support, Female 3
f Body and Stud Assembly 2
g Adapter, Swivel, 1/2 " -27 1
Legend:
Part numbers left blank are not available separately
designates a repair kit item
Repair Kit
Part No. Kit Symbol Description
398719-1 Kit, Repair [Quantity for two (2) Z-Swivels]
Figure 3 High-Pressure Z-Swivel - Exploded View
Changes Since Last Printing
New Format

324400-2
324400-4
324400-5
Service Guide
Alemite Corporation
PO Box 473515, Charlotte, North Carolina 28247-3515
www.alemite.com
Copyright © 2002 by Alemite Corporation
This document contains confidential information that is the property of Alemite Corporation
670432 and is not to be copied, used, or disclosed to others without express written permission. Revision (10-02)
SER 324400-5
Specifications
Piston Diameter x Stroke
Air Inlet Material Outlet
Maximum Air Pressure
Inches Centimeters psi Bars
3 x 1-5/8 7.6 x 4.1 1/4 " NPSI (f) 3/8 " NPTF (f) 200 13.8
Tabl e 1 Air Motor Model 324400 Series Specifications
Description
Overview of Non-Divorced Pumps
The pump tubes that connect to these motors are of a
non-divorced design.
Non-divorced pumps contain a packing group that fits
directly into the lower portion of the motor. This lower
packing group is designed to prevent product from
entering the pneumatic portion of the motor. Product is
distributed through an outlet in the air motor base. See
Figure 1.
Pump tube separation requires that the pump tube
(with attached components) be unthreaded from the base
of the air motor.
Models 324400-2, 324400-4, and 324400-5
The difference between the models in the 324400
series air motors is illustrated in Figure 1.
The obsolete lower packing group in air motor model
324400-2 can be updated with the molded lower packing
group kit that is current in model 324400-4.
These two models contain an obsolete body. Each of
these models can be updated to the current model
(324400-5) with the use of a body replacement kit.
NOTE: With this kit it is necessary to pur-
chase the stepped toggle cap with the o-ring
seal along with the current molded lower
packing group.
Air Motor
Figure 1 Air Motor Model 324400 Series
Model 324400-5 Shown
Air Motor
Model
Toggle Caps Lower Packing Group
Smooth
(w/ Gasket
seal)
Stepped
(w/ O-Ring
seal)
Flat
(Obsolete) Molded
324400-2
324400-4
324400-5
Refer to Figure 6 for details

SER 324400-5 Air Motor
Revision (10-02) 2 Alemite Corporation
Figure 2 Air Motor Model 324400-5 (with High-Pressure Pump Tube Adapter) - Exploded View

Air Motor SER 324400-5
Alemite Corporation 3 Revision (10-02)
NOTE: Additional repair kits for air motor model 324400 series are illustrated on the following page.
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
1 331244 Tube, 5/16 " OD 1 (2)
328306-52 Fitting, Compression 2 Includes items 2-4 (3)
2 Nut, Compression, 1/2 " -24 2 (4)
3 Sleeve, Compression, 5/16 " 2 51017 (40)
4 Elbow, 1/2 " -24 x 1/8 " NPTF (m) 2 131618 (7)
5 331843-4 Cylinder 1 170290 (34)
6 321086 Nut, Piston 1 171000-14 (29)
7 131618 Washer 2 171003-11 (17)
8 321082 Packing (Rubber) 1 171006-15 (10)
9 320749 Spacer 1 171009-29 (23)
10 171006-15 Ring, Retaining 1 171009-41 (18)
11 320748 Washer (Brass) 1 171013-12 (15)
12 314671 Washer (Leather) 1 171636 (22)
13 314670 V-Packing 1 172190-3 (36)
14 320745 Nut, Packing 1 172190-11 (38)
15 171013-12 O-Ring, 1-1/8 " ID x 1-1/4 " OD 2 Qty of 1 in each kit 314670 (13)
16 321087 Adapter 1 314671 (12)
17 171003-11 O-Ring, 2-7/8 " ID x 3-1/8 " OD 1 317524 (30)
18 171009-41 O-Ring, 2-5/16 " ID x 2-1/2 " OD 1 317529 (33)
19 Body 1 320727 (24)
20 Gasket 1 320731 (20)
21 398439 Valve and Seat Assembly (w/ Gasket) 1 320736 (25)
22 171636 Screw, 10- 32 x 3/8 " 4 320737 (32)
23 171009-29 O-Ring, 1-9/16 " ID x 1-3/4 " OD 1 320745 (14)
24 320727 Inlet, Body 1 320746 (35)
25 320736 Shuttle 1 320748 (11)
26 330842 Spring, Valve Retaining 1 320749 (9)
27 330843 Retainer, Valve 1 321082 (8)
28 337471 Cap, Toggle (Stepped) 2 321086 (6)
29 171000-14 O-Ring, 3/4 " ID x 15/16 " OD 2 321087 (16)
30 317524 Spring 2 321457 (31)
31 321457 Plunger 2 328306-52
32 320737 Toggle 2 330842 (26)
33 317529 Muffler 1 330843 (27)
34 170290 Screw, 8 -32 x 1 " 1 331244 (1)
35 320746 Rod, Piston 1 331843-4 (5)
36 Seal, 0.437 " ID x 0.687 " OD 1 337386 (37)
37 Ring, Lantern 1 337387 (19)
38 Seal, 0.437 " ID x 0.937 " OD 1 337394 (39)
39 Washer 1 337471 (28)
40 51017 Gasket, 0.815 " ID (Aluminum) 1 High-Pressure Pump 398439 (21)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
Repair Kits
Part No. Kit Symbol Description Notes
393496-1 Kit, Major Repair See Figure 3
393495 Kit, Lower Packing Group (Includes protective sleeve)
393124 Kit, Cylinder Repair
393533 Kit, Body Repair

SER 324400-5 Air Motor
Revision (10-02) 4 Alemite Corporation
Figure 3 Additional Kits for Air Motor Model 324400 Series- Exploded View

Air Motor SER 324400-5
Alemite Corporation 5 Revision (10-02)
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
8 321082 Packing (Rubber) 1 51017 (40)
10 171006-15 Ring, Retaining 1 171000-14 (29)
12 314671 Washer (Leather) 1 171006-15 (10)
13 314670 V-Packing 1 171009-19 (a)
15 171013-12 O-Ring, 1-1/8 " ID x 1-1/4 " OD 2 Qty of 1 in kit 171009-29 (23)
17 171003-11 O-Ring, 2-7/8 " ID x 3-1/8 " OD 1 171009-41 (18)
19 Body (Obsolete) 1 Model 324400-2 & -4 171013-12 (15)
21 398439 Valve and Seat Assembly (w/ Gasket) 1 171636 (22)
22 171636 Screw, 10- 32 x 3/8 " 4 172190-2 (e)
23 171009-29 O-Ring, 1-9/16 " ID x 1-3/4 " OD 1 172190-3 (36)
25 320736 Shuttle 1 172190-11 (38)
26 330842 Spring, Valve Retaining 1 314670 (13)
27 330843 Retainer, Valve 1 314671 (12)
29 171000-14 O-Ring, 3/4 " ID x 15/16 " OD 2 317524 (30)
30 317524 Spring 2 320724 (42)
31 321457 Plunger 2 320736 (25)
32 320737 Toggle 2 320737 (32)
36 Seal, 0.437 " ID x 0.687 " OD 1 320971 (41)
37 Ring, Lantern 1 321082 (8)
38 Seal, 0.437 " ID x 0.937 " OD 1 321457 (31)
39 Washer 1 321458 (f)
40 51017 Gasket, 0.815 " ID (Aluminum) 1 327329 (19)
41 320971 Pin 1 330842 (26)
42 320724 Cap, Toggle (Smooth) 1 Model 324400-2 & -4 330843 (27)
Kit Items Applicable to Models 324400-2 and 324400-4 337093 (b)
a O-Ring, 1 " ID x 1-3/16 " OD 2 These lower pack-
ing group compo-
nents replace the
obsolete packing
group in Model
324400-2
337096 (c)
bRing 1
337097 (d)
c Adapter 1 337386 (37)
d Ring, Split (Nylon) 1 337394 (39)
e Seal, 0.430 " ID x 0.804 " OD 1 398439 (21)
f 321458 Gasket, 0.885 " ID (Aluminum) 2
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
Repair Kits
Part No. Kit Symbol Description Notes
393496-1 Kit, Major Repair (Includes protective sleeve)
393487 Kit, Lower Packing Group (Includes protective sleeve) Models 324400-2 & -4
393530-2 Kit, Seal [Includes five (5) of item e]
393530-3 Kit, Seal [Includes five (5) of item 36]
393530-11 Kit, Seal [Includes five (5) of item 38]

SER 324400-5 Air Motor
Revision (10-02) 6 Alemite Corporation

Air Motor SER 324400-5
Alemite Corporation 7 Revision (10-02)
IMPORTANT: Prior to performing any
maintenance procedure, the following safety
precautions must be observed. Personal
injury may occur.
WARNING
Do not use halogenated hydrocarbon sol-
vents such as methylene chloride or 1,1,1-trichlor-
ethane in this motor. An explosion can result
within an enclosed device capable of containing
pressure when aluminum and/or zinc-plated parts
come in contact with halogenated hydrocarbon
solvents.
Release all pressure within the system prior to
performing any overhaul procedure.
• Disconnect the air supply line from the motor.
• Into an appropriate container, operate the
control valve to discharge remaining pressure
within the system.
Read each step of the instructions carefully. Make
sure a proper understanding is achieved before
proceeding.
Overhaul
NOTE: Refer to Figures 2 and 3for compo-
nent identification on all overhaul procedures.
Disassembly
Separate Pump from Air Motor
1. Clamp the air motor assembly horizontally in a soft-
jaw vise.
CAUTION
Support the pump tube assembly during removal.
Damage to components can occur.
2. Unscrew the pump tube [with attached components]
from the air motor.
3. Pull on the pump tube to expose the coupling.
4. Remove upper Pin (41) that secures the air motor
Piston Rod to the coupling.
5. Unscrew the coupling from the air motor Piston Rod.
• Rotate the entire pump tube assembly.
6. Remove the adapter from Body (19).
7. Remove O-Ring (15) from the adapter.
8. Remove Gasket (40) from the high-pressure adapter.
Air Motor
Toggle Cap Assembly
1. Unscrew Toggle Caps (28 or 42) from Body (19).
• Use special tool 398500-2. See Figure 4.
2. Remove Springs (30) from each Toggle Cap.
3. Remove O-Rings (29) from each Toggle Cap.
NOTE: Cap (42) seals with Gasket (f).
Cylinder and Upper Packings
4. Remove Screw (34) that secures Muffler (33) to the
Body.
• Remove the Muffler.
5. Loosen each Compression Nut (2) from Elbows (4).
6. Remove Tube (1) [with Compression Sleeves (3) and
Nuts] from the Elbows.
NOTE: The Tube, Compression Sleeve, and
Nut assembly can be reused if no marring or
distortion is visible.
7. Unscrew Cylinder (5) from Adapter (16).
8. Remove O-Ring (17) from the Adapter.
9. Grip the flats of Spacer (9) and unscrew Piston
Nut (6) from Piston Rod (35).
10. Remove Washer (7), Packing (8) and additional Washer
(7) from the Spacer.
Figure 4 Spanner Wrench 398500-2 (Special Tool)

SER 324400-5 Air Motor
Revision (10-02) 8 Alemite Corporation
11. Grip the flats of the Piston Rod and unscrew the
Spacer.
12. Remove the Piston Rod from the Body.
13. Remove Retaining Ring (10) from Packing Nut (14).
• Use internal circlip pliers.
14. Remove Brass Washer (11), Leather Washer (12), and
V-Pack ing (13) from the Packing Nut.
Body Inlet
15. Unscrew Body Inlet (24) from the Body.
• Use the special tool.
16. Remove O-Ring (23) from the Inlet Body.
17. Maneuver Shuttle (25) to remove Plungers (31) from
Toggles (32).
18. Remove the Toggles from the Shuttle.
19. Remove the Shuttle from the Body.
Valve and Seat Assembly
20. Remove Screws (22) that secure Valve Retaining
Spring (26) to the Body.
• Remove the Valve Retaining Spring.
21. Remove the Valve from the Seat.
22. Remove Valve Retainer (27), the Valve Seat, and
Gasket (20) from the Body.
Lower Packing
NOTE: Model 324400-2 contains a packing
group that is obsolete. This model can use
the packing group in:
• model 324400-4
• model 324400-5 with a new Body. See Figure 6.
Model Dependent Step
23. Remove Washer (39), Seal (38), Lantern Ring (37),
and Seal (36) from the Body [model 324400-5].
Remove Adapter (c) [with attached components] and
Ring (b) [with attached components] from the Body.
• Remove Seal (e), O-Ring (a), and Split Ring (d)
from the Adapter.
• Remove Seal (36) from the Ring.
• Remove additional O-Ring (a) from the Body [model
324400-4].
Remove and discard the stacked group from the Body
[model 324400-2].
Optional Procedures
24. Unscrew Elbows (4) from the Cylinder and the Body
as required.
25. Unscrew Packing Nut (14) from the Body as required.
• Remove O-Ring (15).
26. Unscrew Adapter (16) from the Body as required.
• Remove O-Ring (18).
NOTE: The Packing Nut and Adapter are
staked to the Body in three places.
Clean and Inspect
NOTE: Use the appropriate repair kit for
replacement parts. Make sure all the compo-
nents are included in the kit before discard-
ing used parts.
1. Clean all metal parts in a cleaning solvent. The solvent
should be environmentally safe.
2. Inspect all parts for wear and/or damage.
• Replace as necessary.
3. Inspect the large diameter of Piston Rod (35) and the
inside diameter of Cylinder (5) closely for score
marks.
• Replace as necessary.
4. Inspect the Piston Rod for straightness.
• Roll the Piston Rod on a flat surface by hand.
5. Make sure the shoulder of the Piston Rod is square.
6. Closely inspect the mating surfaces of the Valve Seat
and the Valve Slide (21). Ensure a smooth and clean
contact is obtained.
• Replace as necessary.
7. Inspect the bottom of interior bore in Body (19) for
deformity due to excessive hammering.
• Replace the Body with a kit as required.
Assembly
NOTE: Prior to assembly, certain compo-
nents require lubrication. Refer to Ta ble 2
for details.
Air Motor
NOTE: Refer to Figure 6 for a section view
of the Air Motor Assembly.
1. Install O-Ring (18) onto Body (19) as required.
2. Screw and seat Adapter (16) onto the Body.
• Stake the Adapter to the Body in three places. See
Figure 5.
Upper Packing
3. Install O-Ring (15) onto Packing Nut (14) as required.

Air Motor SER 324400-5
Alemite Corporation 9 Revision (10-02)
Item No. Description Item No. Description
Clean Oil
12 Washer (Leather) [Soak 8 hours at room temperature] 23 O-Ring, 1-9/16 " ID x 1-3/4 " OD
13 V-Packing 29 O-Ring, 3/4 " ID x 15/16 " OD
15 O-Ring, 1-1/8 " ID x 1-1/4 " OD 36 Seal, 0.437 " ID x 0.687 " OD
17 O-Ring, 2-7/8 " ID x 3-1/8 " OD 38 Seal, 0.437 " ID x 0.937 " OD
18 O-Ring, 2-5/16 " ID x 2-1/2 " OD e Seal, 0.430 " ID x 0.804 " OD
a O-Ring, 1 " ID x 1-3/16 " OD
Viscous H Lubricant
5 Cylinder - Inside Bore 25 Shuttle - Inside Diameter and Toggle Sockets
8 Packing - Outside Diameter 28 (42) Toggle Cap - Inside Bore
19 Body - 1/4 oz. (7 gms) in Cavity 30 Spring - Coated
21 Valve Slide - Surface in Contact with Spring Retainer 31 Plunger - Outside Diameter and Toggle Socket
NOTE: Part number 398030 is a 2 ounce (57 gm) tube of Viscous H Lubricant
Tabl e 2 Lubricated Components
4. Screw and seat the Packing Nut into Body (19).
• Stake the Packing Nut to the Body in three places. See
Figure 5.
5. Install and seat V-Packing (13) [lip side first], Leather
Washer (12), and Brass Washer (11) into the Packing
Nut.
6. Install Retaining Ring (10) into the Packing Nut.
• Use internal circlip pliers.
Valve, Seat, and Shuttle Assembly
7. Install and seat Gasket (20) and Valve Seat (21) into the
Body.
• Make sure the holes are in alignment.
8. Install and seat Valve Retainer (27) [flat side first] onto
the Valve Seat.
9. Install Valve (21) [concave side first] into the opening of
the Valve Retainer and onto the Valve Seat.
10. Position Valve Retaining Spring (26) onto the Slide
Valve and Valve Retainer.
CAUTION
Do not overtighten Screws (22). Damage to the Valve
Retaining Spring can occur.
11. Install Screws (22) that secure the Valve Retaining
Spring to the Body.
• Torque the Screws alternately in a crisscross
patternto27 inch-pounds (3 Nm) .
Figure 5 Valve Retaining Spring Adjustment

SER 324400-5 Air Motor
Revision (10-02) 10 Alemite Corporation
Figure 6 Air Motor Model 324400 Series - Section View
Refer to Figures 2 and 3Parts List
for Parts Identification

Air Motor SER 324400-5
Alemite Corporation 11 Revision (10-02)
12. Measure the amount of force required to move the
Va l v e o n t h e Va l v e S e a t .
NOTE: The Valve should begin to move with
approximately 8 ounces (227 gms) of force.
If the force is too great or too slight, remove
the Valve Retaining Spring and carefully
bend by hand. See Figure 5.
IMPORTANT: Make sure the smaller inside
diameter on Shuttle (23) points downward.
See Figure 2.
13. Install Shuttle (25) [flat side first and small inside
diameter downward] into the Body and onto the Valve.
14. Install each Toggle (32) onto the Shuttle .
Piston Rod Assembly
15. Install Piston Rod (35) [small diameter first] into the
bottom of the Body and through the Shuttle.
16. Install Spacer (9) [stem end first] onto the top of the
Piston Rod [with Loctite 222] and into the V-Packing.
• Use care not to damage the V-Packing.
17. Screw the Spacer onto the Piston Rod until it seats.
• Grip the flats at the bottom of the Piston Rod.
18. Install Washer (7), Packing (8) and additional Washer
(7) onto the Spacer and Piston Rod.
19. Screw Piston Nut (6) onto the Piston Rod and into the
Washer and Packing.
• Grip the flats of the Piston Rod and tighten the
Piston Nut to 10 foot-pounds (13.5 Nm).
20. Screw Spacer (9) [counterclockwise] against the
Piston Nut.
• Tighten to 20 foot-pounds (27 Nm).
Toggle Caps and Body Inlet
IMPORTANT: Make sure the drain hole on
Plunger (31) points downward.
See Figure 2.
21. Install Plunger (31) [drain hole downward] onto each
Toggle.
22. Install Spring (30) into each Toggle Cap
(28 or 42).
Model Dependent Step
23. Install O-Ring (29) onto each Toggle Cap (28)
[model 324400-5].
Install Gaskets (f) onto Toggle Caps (42)
[models 324400-2 and 324400-4].
CAUTION
Make sure each Toggle is centered in the Shuttle
and the Plunger before Toggle Cap installation.
Damage to the Toggle can occur.
24. Screw the Toggle Caps into the Body.
• Make sure the Spring aligns properly.
• Tighten each Toggle Cap securely with the use of
special tool 398500-2. See Figure 4.
25. Install O-Ring (23) onto Body Inlet (24).
26. Screw the Body Inlet into the Body.
• Tighten the Body Inlet securely with the use of the
special tool.
Cylinder Assembly
27. Install O-Ring (17) onto Adapter (16).
CAUTION
Install Cylinder (5) squarely over the Packing
assembly. Thread damage can occur.
28. Carefully install Cylinder (5) over the Packing
assembly.
• Screw the Cylinder securely onto the Adapter.
29. Apply thread sealant to Elbows (4). See Figure 2.
CAUTION
Do not overtighten the Elbow into the Body. Too
much force can damage the surface used for seat-
ing Valve Assembly (21).
30. Screw the Elbows into the Body and Cylinder.
• Make sure to orient the Elbows properly.
31. Slide Compression Nut (2) [small diameter first] and
Ferrule (3) [large diameter first] onto each end of
Tube (1).
NOTE: The old Tube, Compression Sleeve,
and Nut assembly can be reused if no mar-
ring or distortion is visible.
32. Position the Tube Assembly onto each Elbow.
33. Tighten each Compression Nut securely.
34. Secure Muffler (33) to the Body with Screw (34).
• Tighten the Screw securely.