Alemite 8568 Series User manual

Service Guide
SER 8568-A4
8568 -A4
8568-MA
8568 Series
Alemite, LLC
167 Roweland Drive, Johnson City, Tennessee 37601
www.alemite.com
Copyright © 2005 by Alemite, LLC
This document contains confidential information that is the property of Alemite, LLC
670648 and is not to be copied, used, or disclosed to others without express written permission. Revision (7-05)
Specifications
Pump Tube
Air Motor
Max.
Material Pressure Delivery/Minute (Approximate)* Material Inlet
psi bar gals liters
800 56 3.4 12.9 1-1/2 " NPTF (f)
* For detailed information, refer to Figure 3
Air Motor
Model Piston Dia. x Stroke Air Inlet Material Outlet Max. Air
Pressure
Inches Cm Body Adapter Body Adapter psi bar
324300-3, -4, & -5 2-7/16 x 1-5/8 6.2 x 4.1 1/4" NPSI Not Applicable 3/8 " NPTF Not Applicable 200 14
324300-M 1/4" BSPP (f) x 1/4" NPSI (m) 3/8" BSPT (f) x 3/8" NPTF (m)
Table 1 Medium-Pressure Stub Pump Model 8568 Series Specifications
Description
The major components of an 8568 series pump consist of an
air-operated motor and a pump tube. The air motor connects
directly to the double-acting reciprocating pump tube.
These medium-pressure stub pumps (4:1 ratio) are designed
to deliver a range of light weight oils including gear lubricants.
The pump’s bung adapter [2 " NPTF (m)] allows installation
directly onto original containers or bulk tanks.
Each model stub pump is also designed to accept a variety
of different length and types of extension tubes. These
extension tubes can also be equipped with a low level cut-off
valve. See Table 2.
The pump can also be installed remotely. In this case the
pump threads directly to the appropriate piping hardware.
Model 8568 Series Comparison
Stub pump model 8568-A4 is equipped with air motor
model 324300-5. Pump model 8568-MA is equipped with a
motor that contains BSPP inlet and BSPT outlet adapters.
See Table 1.
All remaining models (with the obsolete piston) were
manufactured with an air motor with standard connections. See
SER 324300-5 for details.
Medium-Pressure Stub Pump
Figure 1 Air Motor Model 8568 Series
Model 8568-MA Shown
Pump Model Piston
w/ O-Ring Seal
(Current) w/o O-Ring Seal (Obsolete)
8568-A4
8568-MA *
8568 Series
NOTE: Figure 5 illustrates the Current and Obsolete Pistons.
* With 324300-M Air Motor (See Table 1).

SER 8568-A4 Medium-Pressure Stub Pump
Revision (7-05) 2 Alemite, LLC
Figure 2 Medium-Pressure Stub Pump Model 8568 Series - Exploded View

Medium-Pressure Stub Pump SER 8568-A4
Alemite, LLC 3 Revision (7-05)
Item
No. Part No. Description Qty Notes Numeric Order
Part # (Item #)
1Motor Assembly, Air * 1 See SER 324300-5 171000-18 (15)
Motor Assembly, Air (w/ Adapters) * 1 X171000-19 (6)
2 328034 Connector, 1/4 " NPTF (m) 1 Model 8568-A4, Series X171013-12 (4)
3 328030 Coupler, 1/4 " NPTF (f) 1 171033-4 (b)
4 X171013-12 O-Ring, 1-1/8 " ID x 1-1/4 " OD 1 Pack of Ten (10) 171033-5 (10)
5 320972 Adapter, Tube 1 171700-36 (12)
6 X171000-19 O-Ring, 1 " ID x 1-1/4 " OD 2 Pack of Ten (10) 319932 (a)
7 320971 Pin, 5/64 " Dia. x 5/8 " Long 1 320952 (20)
8 321615 Rod, Coupling 1 320954 (19)
9 320976 Adapter, Piston 1 320955 (11)
10 171033-5 Pin, Roll, 1/8 " Dia. x 5/8 " Long 1 320971 (7)
11 320955 Spring, Light-Duty, 1-5/32 " Long 1 320972 (5)
12 Ball, 9/16 " Dia. 1 320976 (9)
13 Ring, Wear (Glass-Filled Nylon) 2 321316 (17)
14 Piston 1 321318 (21)
15 O-Ring, 15/16 " ID x 1-3/16 " OD 1 321615 (8)
16 Washer, Back-Up (Nylon) 1 324300-5 (1)
17 321316 Tube and Guide Assembly 1 324300-M (1)
18 326750 Adapter, Bung, 2 " NPTF (m) 1 326750 (18)
19 320954 Spring, Light-Duty, 5/8 " Long 1 328030 (3)
20 320952 Disk, Valve 1 328034 (2)
21 321318 Seat, Valve 1-1/2 " NPT (f) 1 337401 (13)
Additional Kit Items not Applicable to Pump Model 8568 Series 337402 (14)
a 319932 Spring, Heavy-Duty, 1-1/32 " Long 1 337913 (16)
b 171033-4 Pin, Roll, 1/8 " Dia. x 9/16 " Long 1
Legend:
* See Table 1
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
Repair Kits
Part No. Kit Symbol Description
393497 Kit, Major Repair
393565 Kit, Minor Repair (includes ten (10) of each item)
398503-3 Kit, Conversion (used to update pumps with obsolete piston).

SER 8568-A4 Medium-Pressure Stub Pump
Revision (7-05) 4 Alemite, LLC
Accessories
This model pump can be used in a variety of locations which allows an assortment of accessory
items to be utilized. Please refer to Sales Catalog for details on additional accessory items.
Preventive Maintenance
Refer to section entitled Overhaul for the procedures necessary to perform maintenance.
Performance Chart
A pump’s ability to deliver material is based on the pressure (psi/bar) and quantity
(cfm/lpm) of air supplied to the motor and the amount of material discharge [back] pressure to
be overcome within the system.
This chart contains curves based on three different air pressures. The curves relate delivery
in gallons (liters) per minute (X axis) to air consumption in cubic feet (liters) per minute
(right Y axis) and to material discharge pressure in psi/bar (left Y axis).
Part Number Description
321206 Low Level Cut-Off Valve
Table 2 Model 8568 Series Accessory Component
Daily Weekly Monthly Yearly
Wipe Exterior with Clean Cloth Inspect for Air and/or Material Leakage
Table 3 Model 8568 Series Preventive Maintenance Schedule
Figure 3 Delivery versus Discharge Pressure and Air Consumption

Medium-Pressure Stub Pump SER 8568-A4
Alemite, LLC 5 Revision (7-05)
Overhaul
NOTE: Refer to Figure 2 for component
identification on all overhaul procedures.
Prior to performing any maintenance procedure, the following
safety precautions must be observed. Personal injury may occur.
WARNING
Do not use halogenated hydrocarbon solvents
such as methylene chloride or 1,1,1-trichloroethane in this
pump. An explosion can result within an enclosed device
capable of containing pressure when aluminum and/or
zinc-plated parts in the pump come in contact with haloge-
nated hydrocarbon solvents.
Release all pressure within the system prior to performing
any overhaul procedure.
• Disconnect the air supply line from the pump motor.
• Into an appropriate container, operate the 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.
Removal
1. Disconnect the air hose assembly from Air
Motor Assembly (1).
2. Unscrew the pump assembly at Valve Seat
(21) or Bung Adapter (18).
Disassembly
Separate Pump Tube from Air Motor
1. Place the pump assembly in a soft-jaw vise.
• See Figure 4.
2. Unscrew Tube Adapter (5) from the Air
Motor Assembly.
3. Remove Pin (7) that secures Coupling Rod (8)
to the Air Motor Piston Rod.
4. Unscrew the Coupling Rod from the Piston
Rod.
5. Remove the pump tube assembly from the Air
Motor Assembly.
Figure 4 Separation of Pump Tube Assembly from Air Motor
Refer to Figure 2 Parts List
for Parts Identification

SER 8568-A4 Medium-Pressure Stub Pump
Revision (7-05) 6 Alemite, LLC
Item No.
on Figure 2 Description
4O-Ring, 1-1/8 " ID x 1-1/4 " OD
6O-Ring, 1 " ID x 1-1/4 " OD
13 Ring, Wear, (Glass-Filled Nylon)
15 O-Ring, 15/16 " ID x 1-3/16 " OD
16 Washer, Back-Up (Nylon)
Table 4 Lubricated Components
Pump Tube
6. Place the pump tube in a vise at the Valve Seat with the
Coupling Rod facing upward.
7. Remove Tube Adapter (5) from Tube and Guide
assembly (17).
8. Grasp the Coupling Rod and pull the piston assembly
from the Tube and Guide assembly.
NOTE: Use care not to lose Spring (19) and
Valve Disk (20) during the next disassembly
procedure.
9. Remove the Tube and Guide assembly from the Valve
Seat.
• Use the Bung Adapter as a lever.
10. Remove the Spring and the Valve Disk.
CAUTION
Support Rod Coupling (8) and Piston Adapter (9)
during Roll Pin removal. Damage to components
can occur.
11. Remove Roll Pin (8) that secures Piston Adapter (7) to
Coupling Rod (6).
• Use a punch and a small hammer.
12. Unscrew the Coupling Rod from the Piston Adapter.
NOTE: Use care not to lose Spring (11) and
Ball (12) during the next disassembly
procedure.
13. Unscrew the Piston Adapter from the Piston assembly.
14. Remove the Spring and the Ball from the assembly.
IMPORTANT: Should the pump contain the
obsolete piston (see Figure 5), discard the
assembly and use the conversion kit for
replacement.
15. Remove Wear Rings (13), O-Ring (15) and Back-Up
Washer (16) from Piston (14).
16. Remove O-Ring (6) from the Valve Seat.
17. Remove O-Ring (4) and O-Ring (6) from the Tube
Adapter.
18. Remove the Bung Adapter from the Tube and Guide
assembly as required.
Clean and Inspect
NOTE: Use the appropriate repair kit for
replacement parts. Make sure all the compo-
nents are included in the kit and in good
condition before discarding used parts.
1. Clean all metal parts in cleaning solvent. The solvent
should be environmentally safe.
2. Inspect all parts for wear and/or damage.
• Replace as necessary.
3. Inspect Piston (14) closely. Use a magnifying glass to
detect any wire draw marks.
• Replace as necessary.
4. Closely inspect the mating surfaces of all components
for any imperfections. Ensure a smooth and clean
contact is obtained when assembled.
EXAMPLE: Place Ball (12) into Piston
(14). Fill the Piston with solvent. Make sure
no leakage occurs.
5. Measure the depth of the Guide within Tube and
Guide Assembly (17). The distance must be 1-3/16 "
(30 mm). Replace as necessary.
•See
Figure 5.
Assembly
NOTE: Prior to assembly, certain
components require lubrication in clean oil.
Refer to Table 4 for details.
Pump Tube
1. Place Ball (12) into Piston (14).
2. Screw Piston Adapter (9) into the Piston.
• Tighten securely.

Medium-Pressure Stub Pump SER 8568-A4
Alemite, LLC 7 Revision (7-05)
IMPORTANT: Do not mix Springs. Make sure to use
the light-duty spring from the kit. The heavy-duty
spring will not operate in pump model 8568.
3. Install Spring (11) into the Piston Adapter.
• Make sure the Spring centers on the Ball.
Figure 5 Pump Tube 321314 - Section View
4. Screw Coupling Rod (8) into the Piston
Adapter until the pin holes are in alignment.
5. Press on the Ball to ensure it operates and seats
properly.
• Use a small screwdriver or other suitable
tool.
CAUTION
Support the Rod Coupling and the Piston
Adapter during Roll Pin installation. Dam-
age to components can occur.
6. Install Roll Pin (10) to secure the Coupling
Rod to the Piston Adapter.
• Use a small hammer.
7. Install Wear Rings (13), O-Ring (15) and
Back-Up Washer (16) onto the Piston.
8. Install O-Ring (6) onto Valve Seat (21).
9. Install O-Ring (4) and O-Ring (6) onto the
Tube Adapter.
• Make sure to place the larger O-Ring on the
upper portion of the Adapter (with holes).
10. Install Bung Adapter (18) onto Tube and Guide
assembly (17).
• Tighten the Bung Adapter bolt.
11. Install Spring (19) and Valve Disk (20) into the
bottom of the Tube and Guide assembly.
• Make sure the components are stacked and
centered properly.
12. Screw the Valve Seat into the Tube and Guide
assembly. Use care when passing over the
O-Ring.
• Use the Bung Adapter as a lever and tighten
securely.
13. Turn the Tube and Guide assembly end for
end.
CAUTION
Use care not to damage the piston rings
during the installation process.
14. With a slight twisting motion, install the piston
assembly into the Tube and Guide assembly.
• Ease the lubricated assembly past the tube
threads.
Refer to Figure 2 Parts List
for Parts Identification

SER 8568-A4 Medium-Pressure Stub Pump
Revision (7-05) 8 Alemite, LLC
15. Position the top of the Piston Adapter level with the
bottom thread in the tube.
16. Screw Tube Adapter (5) [holes upward] into the Tube
and Guide assembly and tighten securely.
• Use care when passing over the O-Ring.
Connect Pump Tube to Air Motor
17. Place Air Motor assembly (1) in a vise with the piston
rod facing upward.
18. Thread Coupling Rod (8) onto the piston rod until the
pin holes are in alignment.
19. Lubricate Pin (7) with grease to prevent loss during the
installation process.
20. Install the Pin that secures the piston rod to the
Coupling Rod.
21. Thread the Tube Adapter into the air motor and tighten
securely.
• Use care when passing over the O-Ring.
Operation
Bench Test and Prime
NOTE: Perform the following procedures at
a pressure not to exceed 40 psi (2.8 bar).
1. Make sure air pressure at the regulator reads zero.
2. Connect a product hose to the pump’s material outlet.
3. Place the hose into an appropriate collection container.
4. Install Air Connector (2) to the inlet of the Air Motor.
5. Connect an air line to Air Coupler (3).
6. Connect the Air Coupler to the Connector.
7. Slowly supply air pressure to the pump’s motor.
• The pump assembly should cycle.
If the pump assembly does not cycle, refer to the
Troubleshooting Chart for details.
Priming
With air pressure at zero:
8. Place the pump in the product to be dispensed.
9. Slowly supply air pressure to the pump’s motor.
10. Allow the pump to cycle slowly until the system and
product is free of air.
If the pump assembly does not prime, refer to the
Troubleshooting Chart for details.
11.Check the motor for air leakage.
If the motor leaks, refer to the Air Motor Service
Guide for details.
Stall Test
WARNING
Should leakage occur anywhere within the
system, disconnect air to the motor. Personal
injury can occur.
With air pressure at zero:
12. Attach a control valve to the outlet hose of the pump.
13. Set the air pressure to 100 psi (6.9 bar).
14. Operate the control valve into a container.
15. Allow the pump to cycle until the system and product
is once again free of air.
16. Shut off the control valve.
• The pump should not cycle.
If the pump cycles once or continuously, refer to the
Troubleshooting Chart for details.
Installation
Screw the pump assembly into its system at Valve
Seat (21) or Bung Adapter (18).
• Tighten securely.
Additional items that should be incorporated into the
air piping system are illustrated in Table 5.
* Although the air motor is lubricated at the factory,
the life of the motor can be extended with the use of a
lubricator.
Part Number Description
338860 Moisture Separator/Regulator & Gauge Combination
5604-2 Moisture Separator
7604-B Regulator and Gauge
5904-2 Lubricator *
Table 5 Air Line Components

Medium-Pressure Stub Pump SER 8568-A4
Alemite, LLC 9 Revision (7-05)
Troubleshooting Chart
Pump Indications Possible Problems Solution
Pump does not cycle 1. Air motor not operating properly
2. Pump tube jammed and/or contains loose
components
3. Insufficient air pressure
1. Inspect air motor and rebuild or
replace as necessary
2. Rebuild pump tube
3. Increase air pressure
Pump will not prime 1. Excessive cycling speed
2. Pump leaking internally 1. Reduce air pressure 2. See Internal Leaks
Pump cycles rapidly Product source empty Replenish product
Pump cycles continuously,
or slowly (once or twice/
hour)
1. Pump leaking internally
2. Pump leaking externally
3. Distribution system leaking
1. See Internal Leaks
2. See External Leaks
3. Correct leak
External Leaks
Product leakage at outlet
hose Hose connection not tightened sufficiently Tighten connection
Product leakage at control
valve Control valve connection to hose not tightened sufficiently Tighten connection
Product leakage past
O-Ring (4) and visual at top
of Tube and Guide assembly
(17)
1. Initial tightening of Tube and Guide
assembly (17) to Tube Adapter (5) not
sufficient
2. Foreign material between O-Ring (4), Tube
and Guide assembly (17), and
Tube Adapter (5)
3. Damaged O-Ring (4), Tube and Guide
assembly (17), or Tube Adapter (5)
1. Tighten Tube Adapter (5) into Tube
and Guide assembly (17)
2. Disconnect Tube and Guide assembly
(17) from Tube Adapter (5). Clean and
inspect all parts. Locate and eliminate
source of foreign material.
3. Replace any damaged component
Product leakage past
O-Ring (6) and visual at
bottom of Tube and Guide
assembly (17)
1. Initial tightening of Tube and Guide
assembly (17) to Valve Seat (21) not
sufficient
2. Foreign material between O-Ring (6), Tube
and Guide assembly (17), or Valve Seat (21)
3. Damaged O-Ring (6), Tube and Guide
assembly (17), or Valve Seat (21)
1. Tighten Valve Seat (21)
into Tube and Guide assembly (17)
2. Disconnect Valve Seat (21) from Tube
and Guide assembly (17). Clean and
inspect all parts. Locate and eliminate
source of foreign material.
3. Replace any damaged component
Internal Leaks
Product leakage past piston
Wear Rings (13) and/or
O-Ring (15)
1. Worn or damaged Wear Rings (13)
and/or O-Ring (15).
2. Worn or damaged Piston (14)
3. Contamination
1. Disassemble pump, clean and inspect
Wear Rings (13) and O-Ring (15).
2. Inspect Piston (14).
3. Locate and eliminate source of foreign
material.
Product leakage past
Ball (12)1. Foreign material between Ball (12) and Piston (14)
2. Damaged Ball (12)
3. Damaged Piston (14)
Disassemble pump, clean and inspect
seat areas. Check mating surfaces and
replace parts as necessary. Locate and
eliminate source of foreign material.
Product leakage past
Valve Disk (20)1. Foreign material between Valve Disk (20) and Valve Seat (21)
2. Damaged Valve Disk (20)
3. Damaged Valve Seat (21)
4. Damaged Spring (19)
Disassemble pump, clean and inspect
seat areas. Check mating surfaces and
replace parts as necessary. Locate and
eliminate source of foreign material.
Changes Since Last Printing
Changed Air Motor Model 324300-M

SER 8568-A4 Medium-Pressure Stub Pump
Revision (7-05) 10 Alemite, LLC