#3088PL-C 4/2014

MANUAL - PARTS LIST

INSTRUCTIONS!
This manual contains important warnings
and information.
READ AND KEEP FOR REFERENCE.

Autoquip, Inc.
AQ DISPENSER PUMP SYSTEM
#3088 35cc and 70cc Dispenser Pumps

AUTOQUIP, INC. N57 W13430 Reichert Ave. Menomonee Falls, WI 53051

©COPYRIGHT 2014 AUTOQUIP, INC.
 Symbols
Warning Symbol Caution Symbol

WARNING CAUTION
This symbol alerts you to the possibility of This symbol alerts you to the possibility of
serious injury or death if you do not follow damage to or destruction of equipment if you
the instructions. do not follow the instructions.

WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

 This equipment is for professional use only.

 Read all instruction manuals, tags, and labels before operating the equipment.
 Use the equipment only for its intended purpose. If you are not sure, call your Autoquip
distributor.
 Do not alter or modify this equipment. Use only genuine Autoquip parts.
 Check equipment daily. Repair or replace worn or damaged parts immediately.
 Use fluids and solvents that are compatible with the equipment wetted parts.
 Read the fluid and solvent manufacturer’s warnings.
 Always wear protective eyewear, gloves, clothing, and respirator as recommended by the
fluid and solvent manufacturer.
 Comply with all applicable local, state, and national fire, electrical, and safety regulations.

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 WARNING

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.

 Ground the equipment and the object being sprayed

 If there is any static sparking or you feel an electric shock while using the equipment, stop
spraying immediately. Do not use the equipment until you identify and correct the
problem.
 Do not use 1,1,1-trichloroethane, methylene chloride, other Halogenated hydrocarbon
solvents, or fluids containing such solvents in aluminum components. Such use could result
in a serious chemical reaction, with the possibility of explosion.
 Provide fresh ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
 Keep the spray area free of debris, including solvent, rags, and gasoline.
 Before operating this equipment, electrically disconnect all equipment in the spray area.
 Before operating this equipment, extinguish all open flames or pilot lights in the spray area.
 Do not smoke in the spray area.
 Do not turn on or off any light switch in the spray area while spraying or while there any
fumes in the air.
 Do not operate a gasoline engine in the spray area.

HAZARDOUS VAPORS
Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled. When flushing the air motor, keep your face away from the exhaust
port.

United States Government safety standards have been adopted under the Occupational
Safety and Health Act. You should consult these standards – particularly the General
Standards, Part 1910, and the Construction Standards, Part 1926.
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 System Components
PUMP CABINET

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#3088-00-01A DISPENSER MOTOR SECTION

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#3088-70-01A 70cc FLUID SECTION
Non-Flushable

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#3088-35-01A DISPENSER 35CC FLUID SECTION
Non-Flushable

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8
#3088-35-01A DISPENSER 35CC FLUID SECTION
Flushable

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#3088-35-01A DISPENSER 70CC FLUID SECTION
Flushable

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 Piston Dispenser Operation
Material is delivered by a dual acting piston and cylinder type pump. An inlet and an
outlet valve on each end of the cylinder control the material flow. When the piston is moving
down, the bottom inlet valve is closed, and the bottom outlet valve is open. As the piston
moves down, the material in the cylinder below the piston is dispensed thru the bottom outlet
valve. Also as the piston is moving down, the top outlet valve is closed and the top inlet is
open. This allows material to be drawn into the top of the cylinder above the piston. When
the piston gets to the bottom of its stroke, the valve settings and the piston direction reverse.
This causes the material in the top of the cylinder to be dispensed, and the bottom of the
cylinder to be filled.
A balance mechanism is programmed into the PLC control to minimize pressure
fluctuations at piston reversals. This logic assumes that the inlet material pressure is higher
than the dispenser output pressure. This being the case, when the dispenser reaches a travel
position, the inlet valve will close. Thus the inlet side will have both valves closed. The
dispenser will continue movement in the same direction. This continues dispensing material
on the output side while ‘drawing down’ the pressure on the inlet side. At the point where
the inlet side pressure is brought down to match the output pressure, the direction will
reverse. The appropriate valves will open. At this point, the side which was inputting begins
to output and the side which was outputting begins to input.
The position of the piston is relayed to the pump main control by signals from the
position sensor mounted above the stepper motor. The position sensor is a rotary
potentiometer. The device is fitted with a gear that rides on the acme shaft. The two work
as a rack and pinion gear system. As the acme moves up and down with the dispenser
piston, the gear rotates the potentiometer.
The potentiometers resistance value will vary with the dispensers’ position. The
varying resistance from the sensor is used in a voltage bridge to produce a 0-10 volt signal
to the pump control.
Care needs to be taken to maintain the set position of the gear to the acme shaft. If
this position is disturbed or the potentiometer needs to be replaced, the ‘zero’ point will
need to be reset.

 Dispenser Lubrication Oil

The dispenser is equipped with an oil barrier between the dispenser top
seal and the outside air. This is to prevent the hardening of any material which may seep
past the piston top seal. The barrier is contained in the seal spacer area between the upper
and lower seals in the seal block. Always loosen a bleed screw when filling the oil
reservoir.
The oil reservoir should be filled with Seal Oil such as part # G206994 or
equivalent. Appearance of dispensed material (catalyst, etc.) in the oil reservoir is an
indication of worn seals.

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  Dispenser Disassembly
The dispenser should be flushed of material prior to disassembly.
Removing the cylinder will allow the replacement of the piston o-rings. The
cylinder may be removed after first marking and disconnecting all air lines from the
valves and the fluid lines. Remove the 4 tie bolts from the dispenser bottom valve block.
The bottom valve block, tie bolt spacers, and the fluid tubes will all come loose.
Carefully slide the cylinder down and off the piston assembly. The piston o-rings
may then be replaced.
The piston o-rings are Kalreztm material and should be lubricated lightly with
silicone free petroleum jelly prior to installation. The cylinder bore should also be
lubricated when refitting the piston.
The entire dispenser pump may also be removed as an assembly for work on the
bench. This can be accomplished by first removing the air and fluid lines as above.
Remove the bottom shaft coupler set screw and the 4 stand off mounting bolts. The entire
dispenser cylinder assembly will then drop down for removal.
The shaft coupler assembly has two (2) dowel point set screws which engage
fitting holes in the piston and acme shafts. These holes need to be realigned with the
dowel points upon reassembly. Removal of these set screws allows the shafts to be
disengaged from the coupler.
The piston should be fully extended upon reassembly of the cylinder assembly.
This allows the shaft to be repositioned into the coupler when refitting the cylinder to
the cabinet.

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 DISPENSER SHAFT SEAL

 Dispenser Shaft Seals

The shaft seals are fitted into the seal block. Replacing these seal requires the
cylinder assembly to be removed as described above. The seal block may then be
unscrewed from the top valve block.
Remove the seal nut, seals, and seal spacer from the seal block. The o-ring and seal
scraper should also be removed from the top valve block and replaced with new parts.
The seals are the Teflon V packing type. Care should be taken to assure the new seal
parts are orientated in the correct direction. See the parts blow-up for correct assembly
sequence.
Lubricate the seals, the seal block bore and the piston shaft with petroleum jelly.
Fit the new seal pieces into the seal block until they are 1/16 inch above the o-ring
contact surface. Thread the seal nut into the seal block until it contacts the seals and then
back it out two turns.
The seal assembly can then be slid down the piston shaft and tightened into the top
valve block. Tighten the seal nut using the pin provided as a wrench. Seal should be
checked for leakage weekly and tightened as necessary.
Refill the seal oil being sure to loosen the bleed screw until oil appears.

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  Removing Entire Dispenser Assembly
The entire dispenser assembly may be removed from the cabinet. All air and fluid
lines should be removed as above. The stepper motor leads and position sensor wires
need to be disconnected. Removing the 4 bolts from the cabinet mount plate will then
allow the assembly to be removed from the cabinet.

 Dispenser Stepper Motor

The dispenser stepper motor is fitted internally with an acme nut. Stepper operation
causes this nut to rotate. The acme shaft is threaded into the stepper nut. The coupler
guide pin retards rotation of the acme shaft. Thus stepper rotation results in linear motion
of the acme and piston shafts. The position sensor must be removed to replace the stepper
motor. The stepper motor may be removed by removing its bolts and wires and
unthreading it from the acme shaft.
The acme shaft should be lubricated periodically with a small amount of Acme
Thread Lubricant (#4709-00-60A).

 Dispenser Position Sensor Replacement

Replacing the position sensor requires the device ‘zero’ point to be reset.
This is done by removing the top coupler set screw and unscrewing the acme shaft
until it is above the motor stand offs. Carefully pry the piston shaft to its upmost
position. Use a screw driver and appropriate pry blocks to push up on the shaft coupler.
Be careful not to bend or scratch the piston shaft. Remove a top and bottom valve to
ensure that the piston is not hydraulically held by any fluid in the cylinder.
With the piston all the way up, screw the acme shaft down until it is back into
position in the coupler. Refit the coupler set screw. Refit the (new) position sensor and its
gear to the potentiometer holder. Position the gear setscrew to vertical. Slide the holder
with potentiometer and gear into the acme shaft. Adjust this position to give about 0.010
inch of backlash to the acme shaft and tighten the holder screws.
The potentiometer shaft to gear position must be adjusted for proper operation.
This can be done by an ohm meter and alligator clip jumper leads. The potentiometer
wires should be disconnected from the terminal blocks. Attach the ohm meter to the
white wire and black wires with jumper leads. The resistance (ohms) from the
potentiometer can then be measured.
With the gear setscrew loose rotate the potentiometer shaft with a small screw
driver in a clock-wise direction. This would be the same direction it would move with
upward acme shaft movement.
The ohm reading from the potentiometer will go from 0 to 10k ohms with 360
degrees of revolution. The adjustment is made by rotating the shaft counter-clockwise
and dropping the ohm reading until it goes down to 200 - 300 ohms. At this point tighten
the gear set screw. Thus at its topmost position the potentiometer resistance (ohm
reading) is 200 – 300 ohms.
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Dispenser Flow Paths

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  Recommended Spare Parts List

#3088-00-07A Potentiometer Assembly

#3817-00-05B Stepper Motor Control
#3863-55-06C Dispenser Stepper Motor
#3066-41-00A Poppet Color Valve (4)
#4865-01-19A Solenoid Valve (4)
#4709-00-60A Acme Shaft Lubricant
#3863-47-15H Shaft Bushing
35cc Dispenser- #3088-35-02A 35cc Seal Kit
70cc Dispenser- #3088-70-02A 70cc Seal Kit

 Recommended Maintenance

The periodic preventive maintenance of this pump system is centered on the sealing and
valve parts of the system. The operational longevity of these parts is very much determined by
the nature of the material being pumped. Any time increments given are to be used as starting
points.
These dispensers are typically used to pump catalyst (paint hardener). The tendency of
this material to harden (inside the pump and valves) can cause problems. The use of gas
blankets and air driers in the delivery system can reduce problems with moisture sensitive
catalysts. The build up of hardened material on the dispenser piston shaft and / or valve shafts
can accelerate the wear and leaking of their respective seals.

The four (4) poppet color valves used in the dispenser are key to its proper operation. The
seals and o-rings in them are subject to wear and degrading from pumped materials and
contaminants within the operating air stream. The degrading of these valves can result in them
operating sluggishly or sticking (open or closed). Leaking of material from the valve cap is sure
sign of problems. Degrading of the air side o-rings within the poppet valves can also cause them
to stick or possibly leak air into the paint side.
Poppet color valve parts and repair is covered in the #3066V-B Poppet Color Valve
manual. The recommended procedure would be to have four (4) extra valves for bench rebuild
and at maintenance time swap them out. This would save time and allow the removed valves to
be rebuilt at a convenient time for further use. The typical full painting system can have many
of these color valves and it should be noted that those in the catalyst stream will typically
require more frequent attention.
A starting point for valve refurbishing would be 6 month intervals. As little as 3 months
to as long as 12 months depending on conditions and materials could be used for the valves.

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 The dispenser pump itself is also subject to the same build up, o-ring degradation, and
sticking problems as the valves. Again the specific material being pumped will determine the
frequency of maintenance.
All o-rings except the piston o-rings are Teflon™ material. The top piston shaft seals (v-
packing type) are also Teflon™ material. The piston o-rings are Kalrez ™ type material. These
items can be reused if not damaged but should be replaced during any maintenance cleaning.
The v-packing piston shaft seals are “adjustable” and should be tightened if necessary
with the 1/8”x3” pin wrench provided. The seal oil in the tube reservoir should be topped up
also. These items could be preformed on an approximately monthly basis.

The complete fluid section of the pump can be removed by loosening the piston shaft
coupler set screw and removing the stand off bolts (and the air and fluid lines). This can be
done without disturbing the electrical (potentiometer) settings to allow for easy replacement.
A spare shaft coupler assembly (#3088-00-55A) should be installed to allow easy piston
movement on the removed pump. This should be done as any use of pliers or other clamping
device will result in shaft damage and seal leakage. Once removed, the fluid section can then be
disassembled for cleaning and seal / o-ring replacement.
The nature of a piston pump is that it does not have a “flow thru” path and has “eddy”
areas. If a material is prone to solidifying, it can collect in these areas and cause movement
problems. Also solidifying of material around the piston rings during non operation or on the
piston shaft can also cause movement and / or sealing problems.
The necessity of this complete cleaning / reseal is totally dependant on the materials
pumped and usage specifics. Although most users refrain until problems or leakage occurs, a
preventative schedule could be 12 to 24 months cycle.

Two areas in the electrical portion of the pump can be addressed with preventive
maintenance. The acme shaft should be lubricated at about 60 days or when the shaft looks dry
or the grease blackened. Also in high ambient temperatures, a cooling air system can be
installed to reduce component temperatures. This can be a simple needle valve fed with shop air
and set to provide a minimum air flow thru the cabinet.

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 Autoquip Standard Warranty
Autoquip Inc. warrants all equipment manufactured by Autoquip Inc. and bearings its name to be free from defects in material and
workmanship on the date of sale by an authorized Autoquip Inc. distributor to the original purchaser for use. With the exception of
any special, extended, or limited warranty published by Autoquip Inc., Autoquip Inc. will, for a period of twelve months from the date
of sale, repair or replace any part of the equipment determined by Autoquip Inc. to be defective. This warranty only when the
equipment is installed, operated, and maintained in accordance with Autoquip Inc.’s written recommendations.

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

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

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

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

Autoquip Inc. makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in
connection with accessories, equipment, material or components sold but not manufactured by Autoquip Inc. These items sold, but
not manufactured by Autoquip Inc. (such as electric motors, switches, hose, etc.) are subject to the warranty, if any, from their
manufacturer. Autoquip Inc. will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

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

FOR AUTOQUIP, INC. CANADA CUSTOMERS

The parties acknowledge that they required that the present document, as well as all documents, notices and legal proceedings entered
into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent
avoir convenu que la rèdaction du prèsente document sera en Anglais, ainsi que tous documents, avis et procèdures judiciaries
exècutès, donnés ou intentés á la suite de ou en repport, directement ou indirectement, avec les procedures concernées.

Gracotm is a registered trademark of Graco Inc.

Loctitetm is a registered trademark of Loctite Corp.
Kalreztm is a registered trademark of Dupont Co.

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 Autoquip Phone Numbers
TO PLACE AN ORDER, contact your Autoquip distributor, or call this number to identify the distributor closest to you :
(262) 781-6133 Fax (262) 781-6188

All written and visual data contained in this document reflects the latest product information available at the time of publication.
Autoquip reserves the right to make changes at any time without notice.

Sales Offices : Menomonee Falls, WI (262) 781-6133 Fax (262) 781-6188

AUTOQUIP, INC. N57 W13430 Reichert Ave. Menomonee Falls, WI 53051

http://www.aqautomation.com
PRINTED IN USA May 2012

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