Alemite 7818-F4 User manual

Service Guide
SER 7818-F5
Alemite Corporation
167 Roweland Drive, Johnson City, Tennessee 37601
www.alemite.com
Copyright © 2004 by Alemite Corporation
This document contains confidential information that is the property of Alemite Corporation
670772 and is not to be copied, used, or disclosed to others without express written permission. Revision (6-04)
7818-F4
7818-F5
Figure 1 Pump Hoist Model 7818-F5
Description
Model 7818-F5 is a double-post hoist (with
follower plate) designed to accommodate
pump assemblies (see Table 1) capable of
pumping medium- to heavy-weight material
from original 400-pound (180 kg) containers.
The air-operated power ram raises and
lowers the pump (not included) and follower
plate assembly. Pressure created from the
force on the follower plate causes the material
to enter the inlet of the pump.
Force and Pressure
The power ram develops a force of 1050
pounds (477 kg) on the follower when 100 psi
(6.9 Bars) of air pressure is applied to the
hoist. This translates into a pressure of 2.5 psi
on the material within a 400-pound container
(0.16 Bar for a 180 kg container).
Control Box
A pneumatic control box mounts to the left
column of the hoist. The operator positions
three separate valves to control the flow of air
to the hoist, pump’s motor, and follower plate.
Models 7818-F4 and 7818-F5
Model 7818-F4 is obsolete.
Pump and Adapter
Pump Model Ratio Adapter *
7785-A5 40:1 327247
7786-A5 75:1
7886-A5 11:1 330976
7889-C 40:1 327247
7896-A5 22:1 330976
* See Figure 3 for details
Table 1 Pump and Adapter Usage
Pump Hoist and Power Ram
Hoist
Model
Overall Height Width x Depth Follower
Plate
Maximum
Air Pressure
Down Position Up Position
Inches Meters Inches Meters Inches Meters psi Bars
7818-F4 69 1.75 106 2.69 42 x 24 1.07 x .61 None 200 14
7818-F5 327690
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SER 7818-F5 Pump Hoist and Power Ram
Revision (6-04) 2 Alemite Corporation
Figure 2-A Pump Hoist Model 7818-F5 - Exploded View
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Pump Hoist and Power Ram SER 7818-F5
Alemite Corporation 3 Revision (6-04)
Item
No. Part No. Description Qty Model Notes Numeric Order Part # (Item #)
1 Nut, 11/16 " -24 2
Both
1650 (22)
2 331201 Rod 1 11775 (35)
3 Nut, 3/4 " -16 2 45120 (23)
4 Lockwasher, 3/4 " 2 76925 (4)
5 324957-2 Bridge 1 77783 (30)
6 Pin, Roll, 1/2 " x 3 " Long 2 77890 (25)
7 324958 Rod 2 79832 (3)
8 326896 Rod, Piston 2 170008 (21)
9 Pin, 5/8 " x 3 " Long 2 171001-38 (14)
10 Cap 2 171040-9 (6)
11 Washer (Leather) 2 171651 (28)
12 Packing, Block-V 2 172207-3 (31)
13 324968 Bushing 2 172207-4 (26)
14 O-Ring, 2-3/4 " ID x 3-1/8 " OD 2 315703 (24)
15 Spacer 2 316090 (12)
16 Gasket (Aluminum) 4 316091 (11)
17 Packing, Block-V 4 316093 (10)
18 331048 Piston 2 316094 (19)
19 Bolt, 7/8 " -14 x 5-1/2 " 2 316098 (16)
20 Column 2 316100 (9)
21 170008 Plug, 1/4 " NPTF (m) 5 316102 (15)
22 1650 Fitting 2 7818-F5 318812 (32)
23 45120 Bushing, 1/4 NPTF (m) x 1/8 " NPTF (f) 2 318815 (33)
24 U-Bolt, 3/8 " -16 5
Both
319299 (1)
25 Nut, 1/2 " -13 8 324957-2 (5)
26 Lockwasher, 1/2 " 8 324958 (7)
27 Base 1 324965 (34)
28 Screw, 1/2 " -13 x 2-1/2 " 8 324968 (13)
29 327690 Plate Assembly, Follower 1 7818-F5 See Figure 2-E 324975-B4 (20)
30 Nut, 3/8 " -16 10
Both
326896 (8)
31 Lockwasher, 3/8 " 10 327690 (29)
32 318812 Shoe 2 330298-2 (27)
33 318815 Spring 2 331048 (18)
34 324965 Brace 1 331049 (17)
35 Screw, 1/2 " -13 x 2-1/2 " 2 331201 (2)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
Repair Kit
Part No. Kit Symbol Description
393703 Kit, Cylinder Repair
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SER 7818-F5 Pump Hoist and Power Ram
Revision (6-04) 4 Alemite Corporation
Figure 2-B Pump Hoist Model 7818-F5 - Exploded View (Control Box)
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Pump Hoist and Power Ram SER 7818-F5
Alemite Corporation 5 Revision (6-04)
Item
No. Part No. Description Qty Model Numeric Order
Part # (Item #)
36 Screw, 10-32 x 3/8 " 4
Both
SWA 274 (47)
37 324951-2 Bracket 1 1002-88 (46)
38 45120 Bushing, 1/4 NPTF (m) x 1/8 " NPTF (f) 2 17412 (36)
39 Elbow, Compression, 1/8 " NPTF (m) x 1/8 " Tube 2 43760 (41)
40 Tee, 1/8 " 1 44494 (50)
41 43760 Adapter, 1/8 " NPTF (m) x 1/4 " NPTF (f) 1 45120 (38)
42 Tubing, 1/8 " OD x 6 " Long 1 51891 (52)
43 324698 Valve (Follower Plate) 1 61463 (57)
44 306722 Adapter, 1/4 " NPTF (m) x 1/8 " NPTF (m) 1 171508 (58)
45 329741 Valve (Hoist) 1 172261-1 (51)
46 1002-88 Union, 1/2 " NPTF (m) x 1/2 " NPSM (f) 1 172261-3 (49)
47 SWA 274 Valve, Ball, (Pump Motor) 1 172263-1 (48)
48 Nipple, 1/2 " NPTF x 1-1/8 " Long 1 306722 (44)
49 Nipple, 1/4 " NPTF x 1-3/8 " Long 1 311539 (40)
50 Elbow, 1/4 " NPTF 1 311544 (53)
51 Nipple, 1/4 " NPTF x 7/8 " Long 1 324698 (43)
52 51891 Adapter, 1/2 " NPTF (m) x 1/4 " NPTF (f) 1 324951-2 (37)
53 311544 Tee, 1/2 " 1 328032 (56)
54 329742-2 Cover 1 328033 (55)
55 328033 Connector 1 328306-22 (39)
56 328032 Coupler, 3/4 " NPTF (f) 1 329741 (45)
57 Lockwasher, 10 4 329742-2 (54)
58 Screw, 10-24 x 1/2 " 4 384317-6 (42)
Legend:
Part numbers left blank (or in italics) are not available separately
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SER 7818-F5 Pump Hoist and Power Ram
Revision (6-04) 6 Alemite Corporation
Figure 2-C Pump Hoist Model 7818-F5 - Exploded View (Up Tubing)
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Pump Hoist and Power Ram SER 7818-F5
Alemite Corporation 7 Revision (6-04)
Figure 2-D Pump Hoist Model 7818-F5 - Exploded View (Down Tubing)
Item
No. Part No. Description Qty Model Numeric Order Part # (Item #)
59 317811-5 Hose Assembly, 1/2 " ID x 60 " Long [1/2 " NPTF (m)] 1
Both
76550 (67)
60 Tubing, 3/8 " OD x 50 " Long 1 76784 (70)
61 Connector, Compression, 1/4 " NPTF (m) x 3/8 " Tube 2 76895 (69)
62 Tubing, 3/8 " OD x 50 " Long 1 307416 (68)
63 Connector, Compression, 1/8 " NPTF (m) x 3/8 " Tube 2 311539 (64)
64 Tee, 1/8 " 1 317811-5 (59)
65 Connector, Compression, 1/8 " NPTF (m) x 3/16 " Tube 2 318810-D (62)
66 Tubing, 3/16 " OD x 22 " Long 1 318810-E (60)
67 Screw, 6-32 x 5/8 " 3 318810-F (73)
68 Clamp 3 324964-1 (66)
69 Lockwasher, 6 3 328303-32 (65)
70 Nut, 6-32 3 328303-62 (63)
71 Hose, 1/4 " ID [1/4 " NPTF (m) x 7/16 " -20 UNF-2B 1 328303-64 (61)
72 Elbow, Compression, 1/4 " NPTF (m) x 3/8 " Tube 2 328306-64 (72)
73 Tubing, 3/8 " OD x 82 " Long 1 337482-A1 (71)
Legend:
Part numbers left blank (or in italics) are not available separately
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SER 7818-F5 Pump Hoist and Power Ram
Revision (6-04) 8 Alemite Corporation
Figure 2-E Pump Hoist Model 7818-F5 - Exploded View (Follower Plate Model 327690)
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Pump Hoist and Power Ram SER 7818-F5
Alemite Corporation 9 Revision (6-04)
Item
No. Part No. Description Qty Model Notes Numeric Order Part # (Item #)
74 315755 Nut and Handle Assembly, Follower 1
7818-F5
45370 (75)
75 45370 Screw, 9/16 " -12 x 1-1/4 " 4 45496 (77)
76 327245 Gasket 1 76925 (86)
77 Plug, 1/2 " NPT (m) 1 79832 (85)
78 Plate, Follower 1 w/o Plug A 170304 (80)
79 324685 Valve, Flat 1 315755 (74)
80 Screw, 10-32 x 3/16 " 2 323657 (84)
81 Clamp 2 324685 (79)
82 Hose, Wiper, 68 Long 1 327245 (76)
83 Hose, Wiper, 68-5/8 " Long 1 327691 (78)
84 323657 Nut, 9/16 " -12 4 327694-1 (82)
85 Nut, 3/4 " -16 2 327694-2 (83)
86 Lockwasher, 3/4 " 2339409 (81)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
Repair Kit
Part No. Kit Symbol Description
393704 Kit, Follower Hose
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SER 7818-F5 Pump Hoist and Power Ram
Revision (6-04) 10 Alemite Corporation
Installation and Operation
NOTE: Refer to Figures 2-A through 2-E
and Figure 3 for component identification on
the installation and operational procedures.
WARNING
Do not exceed the lowest pressure rating
of any component in the system.
Read each step of the instructions carefully. Make
sure a proper understanding is achieved before
proceeding.
Figure 3 Follower Plate Pump Adapters
Adapter Attachment to Pump
IMPORTANT: The adapter used is depen-
dent on the model of the pump. See Table 1.
Adapter Model 327247
1. Remove the original primer body from the pump.
2. Remove the nut that secures the primer plate to the
primer rod.
3. Remove the valve seat from the pump tube and discard
both aluminum gaskets.
4. Install and seat Gasket (b), the valve seat, and
additional Gasket (b) into the pump tube.
5. Secure the plate to the primer rod with the nut.
•Tighten the nut securely.
6. Screw Adapter (c) [with Loctite 222] into the pump
tube.
•Tighten the pump tube securely.
Adapter Model 330976
7. Screw Adapter (d) onto the pump tube [with
Loctite 222].
•Tighten the pump tube securely.
Pump Attachment to Hoist
8. Loosen Nuts (1) that secure Rod (2) to Bridge (5).
9. Remove the pipe plug from the top of the air motor.
10. Position the pump assembly onto Follower Plate
Assembly (29).
11. Thread the Rod (with thread sealant) into the pump’s
air motor until it bottoms.
•Tighten the Rod securely.
12. Turn top Nut (1) to raise the pump assembly slightly
off the Follower Plate Assembly
13. Position Gasket (76) onto the Follower Plate.
•Make sure the holes are in alignment.
14. Install Screws (75) into the pump’s adapter.
•This aids in aligning the pump with the Gasket and
Follower Plate Assembly.
15. Turn top Nut (1) to lower the pump assembly onto the
Gasket and Follower Plate.
IMPORTANT: Both Nuts are secured to the
hoist once the Follower Plate is attached.
Item
No. Part No. Description Qty
a 327247 Kit, Adapter 1
b 131402 Gasket 2
c 332469 Adapter, 1-3/4 " -20 1
d 330976 Adapter, 2" -16 1
Legend:
Part numbers left blank are not available separately
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Pump Hoist and Power Ram SER 7818-F5
Alemite Corporation 11 Revision (6-04)
16. Check to ensure the position of each of the three (3)
hoist’s valve handles is as shown in Figure 4.
17. Attach an air line to the inlet of the hoist.
18. Set the air pressure regulator to 100 psi (6.9 Bars).
19. Place the Hoist’s Valve Handle in the Up position.
•See Figure 4.
Allow the hoist to rise to a height that provides access
to the bottom of the Follower Plate.
WARNING
Position a stable support underneath the
Follower Plate.
Personal injury can occur.
20. Thread Nuts (84) onto Screws (75).
•Tighten the Nuts securely in an alternate pattern.
21. Remove the support and lower the Follower Plate onto
the Base of the hoist.
•Place the Hoist’s Valve Handle in the Down
position.
22. Thread top Nut (1) on Rod (2) until it contacts
Bridge (5).
•Repeat the process for the bottom Nut.
23. Tighten each Nut alternately and evenly until secure.
Hose Attachment
Pump Motor
24. Screw Hose (59) [with thread sealant] to the inlet of
the pump’s motor.
•Tighten the Hose securely.
25. Screw the opposite end of the Hose to Union (46).
•Tighten the Union securely.
Follower Plate
26. Screw Hose (71) [with thread sealant] into Follower
Plate (78).
•Tighten the Hose securely.
27. Screw the opposite end of the Hose to Valve (43).
•Tighten the Hose securely.
Operation
IMPORTANT: Hoist operation may vary.
Please read the following procedures care-
fully.
WARNING
Never point a control valve at any portion
of your body or another person. Lubricant dis-
charged at high velocity can penetrate the skin and
cause severe injury. Should product appear to
puncture the skin, get medical care immediately.
Ensure all components are in operable condition.
Replace any suspect parts prior to operation.
Personal injury can occur.
Getting Started
1. Attach a material hose (with control valve) to the
outlet of the pump.
2. Lubricate both wipers on the follower plate with the
material to be pumped.
Figure 4 Control Box Valves
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SER 7818-F5 Pump Hoist and Power Ram
Revision (6-04) 12 Alemite Corporation
3. Unscrew Nut and Handle Assembly (74) on Follower
Plate Assembly (78).
•This allows air trapped underneath the Follower
Plate to bleed.
4. Place the Hoist’s Valve Handle in the Up position.
5. Center the container onto Base (27) once the hoist
stops.
•Make sure each Shoe (32) properly secures the
container.
6. Place the Hoist’s Valve Handle in the Down position.
•Allow the Follower Plate to enter the container.
Force will cause product to appear at the Follower
Plate’s bleed valve and the hoist should stall.
7. Screw the Nut and Handle Assembly securely on the
Follower Plate.
CAUTION
Leaving the Hoist’s Valve Handle in the Down posi-
tion may cause the material to bypass the fol-
lower’s wiper hoses.
Whether to place the Hoist’s Valve Handle in the
Neutral position or maintain the Down position is
dependent on the:
•viscosity of the material being pumped
•amount of line pressure to the hoist
Dependent Step
8. Place the Hoist’s Valve Handle in the Neutral position
as required.
9. Rotate the Pump’s Valve Handle to the On position.
10. Check the motor for air leakage.
If the motor leaks, refer to the Troubleshooting Chart
in the Air Motor Service Guide for details.
11. Operate the control valve into a container.
12. Allow the pump to cycle until the product is free of air.
If the pump assembly does not prime, refer to the
Troubleshooting Chart in the Pump Service Guide for
details.
13. Shut off the control valve.
14. Visually inspect the pump for external leaks.
•The pump should not cycle.
If the pump does not stall, refer to the
Troubleshooting Chart in the Pump Service Guide for
details.
Once the Container is Empty
15. Place the Follower Plate’s Valve Handle to the On
position (in line with the hose).
16. Place the Hoist’s Valve Handle in the Up position.
Air enters beneath the follower plate to assist the hoist.
Once the follower plate is free of the container:
17. Place the Hoist’s Valve Handle in the Neutral
position.
18. Place the Follower Plate’s Valve Handle in the Off
position.
Preventive Maintenance
Daily Yearly
Inspect for Air and/or Material Leakage Attach gun to Fitting (22) and add 2 oz. (59 cc) of clean SAE 30 oil to each column
Table 2 Pump Hoist Model 7818-F5 Preventive Maintenance Schedule
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Pump Hoist and Power Ram SER 7818-F5
Alemite Corporation 13 Revision (6-04)
3. Unscrew each Cap (10) from each Column.
• Use a drift and hammer.
4. Remove the entire Piston assembly from each Column.
5. Remove Bushing (13) from the Piston.
6. Remove Washer (11), Block-V Packing (12), and
O-Ring (14) from the Bushing.
7. Remove both Block-V Packings (17) from Piston (18).
8. Remove Pin (9) from Piston Rod (8) as required.
9. Unscrew Bolt (19) from the Piston Rod as required.
10. Remove Spacer (15), Gasket (16), Piston (18), and
additional Gasket (16) from the Bolt.
Clean and Inspect
1. Clean all metal parts in a modified petroleum-based
solvent. The solvent should be environmentally safe.
2. Inspect the bore of Column (20) for wear and/or
corrosion.
If the bore of either Column requires cleaning:
3. Unscrew Hose (59) from Union (46).
4. Remove the Bridge assembly from the hoist’s Base.
5. Detach the Base from its foundation.
6. Position the Base assembly to allow access to the
Column’s bore.
To clean the bore of the Column:
7. Attach a 3-1/4 “ (8.3 mm) diameter wire brush to a
tube or other suitable holder.
• Rotate the assembly during the cleaning process.
8. Remove any contaminants from within the Column.
Assembly
NOTE: Prior to assembly, certain compo-
nents require lubrication. Refer to Table 3
for details.
Prior to Overhaul
NOTE: The following procedures pertain to
the hoist’s cylinders and the Follower Plate.
Operate the hoist and allow the Follower Plate to
contact the Base.
HINT: Allow the Follower Plate to contact
a box or other suitable structure. The struc-
ture provides easier:
• removal of the bridge assembly from the Base, if
required
• detachment of the Follower Plate from the hoist
Overhaul
Prior to performing any maintenance procedure, the
following safety precautions must be observed. Personal
injury may occur.
WARNING
Release all pressure within the system
prior to performing any overhaul procedure.
• Disconnect the air supply line from the
control box.
• Into an appropriate container, operate the
pump’s control valve to discharge remaining
pressure within the system.
Never point a control valve at any portion of your
body or another person. Accidental discharge of
pressure and/or material can result in injury.
Read each step of the instructions carefully. Make
sure a proper understanding is achieved before
proceeding.
NOTE: Refer to Figures 2-A through 2-E
for component identification on all overhaul
procedures.
Hoist Cylinder
Disassembly
1. Remove Roll Pins (6) that secure Bridge (5) to Piston
Rods (8).
• Use a drift and hammer.
2. Rotate the Bridge assembly to expose the top of
Columns (20).
Item No. Description Type of Lubricant
11 Washer (Leather)
Gear Oil
12 Block V-Packing
14 O-Ring, 2-3/4 " ID x 3-1/8 " OD
17 Block V-Packing
20 Bore of Column Mobilith AW-1
Table 3 Lubricated Components
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SER 7818-F5 Pump Hoist and Power Ram
Revision (6-04) 14 Alemite Corporation
1. Install Block-V Packings (17) onto Piston
(18).
•See
Figure 5 for the proper orientation of
the Packings.
2. Install and seat Gasket (16), the Piston
assembly, additional Gasket (16), and
Spacer (15) onto Bolt (19).
3. Screw the Bolt assembly into Piston Rod
(8).
• Tighten the Bolt securely.
4. Install and center Pin (9) in the Piston Rod.
CAUTION
Use care during the installation of the
Piston assembly. Damage to the Block-V
Packings can occur.
5. Install the Piston assembly into Column
(20).
6. Install O-Ring (14) onto Bushing (13).
7. Install the Bushing assembly onto the
Piston and into the Column.
8. Install Block-V Packing (12) [lips
downward] and Washer (11) over the Piston
and into the Bushing.
• Use care passing the cross-hole in the
Piston.
• Make sure both components seat properly
within the Bushing.
9. Screw Cap (10) onto the Column.
• Tighten the Cap securely.
10. Install the Bridge assembly onto each
Piston Rod.
• Make sure the pin holes are in alignment.
11. Install Roll Pins (6) that secure the Piston
Rods to Bridge (5).
Figure 5 Hoist Column- Section View
Refer to Figure 2-A Parts List
for Parts Identification
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Pump Hoist and Power Ram SER 7818-F5
Alemite Corporation 15 Revision (6-04)
Follower Plate
Assembly
Hoses to Follower Plate
NOTE: Refer to Figure 2-E for component
identification on the following procedures.
1. Insert Clamp (81) into upper Hose (83).
IMPORTANT: Hose (83) is slightly longer
than lower Hose (82).
2. Coil the Hose assembly into the upper groove of
Follower Plate (78).
HINT: Position the Follower Plate assembly
on its outer circumference with the Clamp
opening upward.
Changes Since Last Printing
Deleted Pump Models 7785-B5 and 7786-C from Table 1
3. Draw the Clamp tight against the Hose and Follower
Plate.
4. Close the opening in the Hose.
• Hammer the Hose with a wooden or rubber mallet.
• Make sure the ends butt squarely.
5. Repeat steps 1 through 4 for lower Hose (82).
IMPORTANT: Make sure the opening on the
Lower Hose is 180 ° opposite the upper
Hose.
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SER 7818-F5 Pump Hoist and Power Ram
Revision (6-04) 16 Alemite Corporation
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