Alemite 9616-A User manual

Service Guide
SER 9616-A
9616-A
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
670546
and is not to be copied, used, or disclosed to others without express written permission.
Revision (10-98)
2 " NPTF (m)
[1-1/2 " NPTF (f)]
Air Inlet Material
Outlet
Material
Inlet
Shut-Off Valve
Figure 1 Low-Pressure Transfer Pump Model 9616-A
Description
The major components of model 9616-A transfer
pump consist of an air-operated motor and a pump tube.
The air motor connects directly to the double-acting
reciprocating pump tube.
This low-pressure (1:1 ratio) transfer pump is
designed to deliver a range of light weight oils including
gear lubricants.
Mounting
This pump mounts directly onto original containers or
bulk tanks that have a 2 " NPTF bung fitting. The
required length downtube screws directly into the 1-1/2 "
NPTF female threads in the valve body.
As an alternative, the pump can also mount to a wall
(with the use of a wall bracket) and be used with an
optional suction hose. See Table 2 for details.
Also, the pump screws directly onto two different size
threaded standpipes [1-1/2 " NPTF (m) or 2 " NPTF (f)].
Specifications
Air Motor
Pump Tube
Piston Diameter x Stroke Air Inlet
Max. Air
Pressure
Inches Millimeters psi Bars
2-15/16 x 3 74.6 x 76.2 1/4 " NPTF (f) 150 10.3
For information on the air motor, refer to SER 338066-A1
Max. Material
Pressure Delivery/Minute (Approximate) Material Outlet
psi Bars Gallons Liters w/Bushing w/o Bushing
150 10.3 16 60.6 1/2 " NPTF (f) 3/4 " NPTF (f)
* For detailed information, refer to Figure 3 .
Table 1 Model 9616-A Specifications
Low-Pressure Transfer Pump
Overall Height Weight
Inches Meter lbs kg
15-7/8 0.4 13 5.9
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SER 9616-A Low-Pressure Transfer Pump
Revision (10-98) 2 Alemite Corporation
34
26
11
T
H
I
S
S
I
D
E
U
P
1
2
3
4
5
6
7
8
9
10
10
12
13
14
15
16
17
18
19
20
21
22
5
23
27
29
30
31
32
33
24
25
Point Ground
Side Upward
Place Punch Here
Apply Thread
Sealant Here
Apply Thread
Sealant Here
28
Weep
Hole
a
Figure 2 Low-Pressure Transfer Pump Model 9616-A - Exploded View
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Low-Pressure Transfer Pump SER 9616-A
Alemite Corporation 3 Revision (10-98)
Repair Kits
Part No. Kit Symbol Description
393627 Kit, Major Repair (Includes tube of 393590 Teflon Grease)
393530-24 Kit, Seal [includes five (5) of item number 13 ]
393530-26 Kit, Seal [includes five (5) of item number 15 ]
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
1 328030 Coupler, Air, 1/4 " NPTF (f) 1 51929 (5)
2 330605 Adapter, 1/4 " NPTF (f) 1 171000-7 (8)
3 319391 Valve, Shut-Off 1
171000-103
(7, a)
4 Motor Assembly, Air 1 See SER 338066-A1 171003-10 (10)
5 51929 Nut, Elastic Stop 2
171006-17
(17)
6 338111 Piston, Air 1
171009-14
(30)
7 O-Ring, 2-5/8 " ID x 3 " OD 1
171009-27
(25)
8 171000-7 O-Ring, 3/8 " ID x 1/2 " OD 1 171009-35 (33)
9 338109 Washer, 3/8 " 1
171016-50
(19)
10 171003-10 O-Ring, 2-3/4 " ID x 3 " OD 2 171700-56 (29)
11 Body, Outlet 1
172190-24
(13)
12 320531 Bushing, 3/4 " NPTF (m) x 1/2 " NPTF (f) 1
172190-26
(15)
13 Seal, 1/2 " ID x 3/4 " OD 1 319391 (3)
14 338072 Ring, Lantern (Brass) 1 320531 (12)
15 Seal, 1/2 " ID x 7/8 " OD 1 323474 (16)
16 323474 Washer 1 328030 (1)
17 Ring, Retaining, Internal 1 330605 (2)
18 338589 Rod 1
338066-A1
(4)
19 Ring, Retaining, External 1 338072 (14)
20 338271 Piston, Fluid (Nylon) 1 338109 (9)
21 Gasket (Aluminum) 1 338111 (6)
22 338259 Plate (Stainless Steel) 1 338259 (22)
23 338591 Stop 1 338261 (26)
24 338590 Pin, 1/4 " Dia. x 1-5/8 " Long 1 338271 (20)
25 O-Ring, 1-7/16 " ID x 1-5/8 " OD 1
338272
(21)
26 338261 Cylinder 1 338283 (27)
27 338283 Ring 1
338588
(11)
28 338594 Screw, 5/16 " -18 x 2-1/2 " 4 338589 (18)
29 171700-56 Ball 1 338590 (24)
30 O-Ring, 1-1/4 " ID x 1-3/8 " OD 1 338591 (23)
31 338592 Seat 1 338592 (31)
32 338595 Spring, Disc 4 338593 (34)
33 171009-35 O-Ring, 1-15/16 " ID x 2-1/8 " OD 1 338594 (28)
34 338593 Body, Valve 1 338595 (32)
Kit Component for Model 9616-S
a O-Ring, 2-5/8 " ID x 3 " OD 1
Legend :
Part numbers left blank (or in italics ) are not available separately
designates a repair kit item
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SER 9616-A Low-Pressure Transfer Pump
Revision (10-98) 4 Alemite Corporation
16
Legend:
Air Pressure
Material Discharge Pressure
Air Consumption
Material Discharge Pressure (psi)
Air Consumption (cfm)
00
SAE 10 Oil at 77 ° F
2 4 6 8 10 12 14
20
40
60
80
100
120
140
160
0
4
8
12
16
20
24
28
32
Gallons per Minute
Liters per Minute
lpm
cfm
psi
Bars
100
200
300
400
500
600
700
800
10 20 30 40 50 60
100 psi (6.9 Bars)
150 psi (10.3 Bars)
50 psi (3.4 Bars)
50 psi (3.4 Bars)
150 psi (10.3 Bars)
100 psi (6.9 Bars)
1
2
3
4
5
6
7
8
9
10
11
Delivery
Accessories
Performance Curves
A pump’s ability to deliver material is based on the pressure (psi/Bars) 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/Bars (left Y axis).
Extension Description
Drum Tank
16-Gallon 55-Gallon 250-Gallon
Bench-Top 275-Gallon Obround
V-Cut 338147-3 338147-4 338147-8 338147-9
Threaded at both ends * 338246-3 338246-4 338246-8 338246-5
* NOTE : For use with low level cut-off valve part number 321206
Additional Accessories
Low Level Cut-Off Valve 321206
Siphon Kit SWA 306
Wall Bracket 325749
Metal Discharge Hose (4-Feet) 338360
Table 2 Model 9616-A Accessory Components
Figure 3 Delivery versus Discharge Pressure and Air Consumption
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Low-Pressure Transfer Pump SER 9616-A
Alemite Corporation 5 Revision (10-98)
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 sol-
vents such as methylene chloride or 1,1,1 trichlo-
roethane 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 halogenated
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.
Disassembly
Separate Air Motor from Pump Tube
1. Clamp the pump assembly in a soft-jaw vise.
2. Remove Capscrews ( 28 ) that secure Ring ( 27 ),
Cylinder ( 26 ), and Air Motor Assembly ( 4 ) to Outlet
Body ( 11 ).
• Remove the Ring from the Cylinder.
3. With a side-to-side motion, pull the Air Motor
Assembly from the Outlet Body.
• Lubricate upper O-Ring ( 10 ) with oil to ease
separation.
NOTE : The following three (3) steps are
performed only as required.
4. Remove Coupler ( 1 ) from Adapter ( 2 ).
5. Unscrew the Adapter from Shut-Off Valve ( 3 ).
6. Unscrew the Shut-Off Valve from the Air Motor
Assembly.
Pump Tube Assembly
7. With a side-to-side motion, pull the Cylinder assembly
from the Outlet Body.
• Lubricate lower O-Ring ( 10 ) with oil to ease
separation.
8. Unscrew Bushing ( 12 ) from the Outlet Body as
required.
9. Remove O-Rings ( 10 ) from the Outlet Body.
10. Remove O-Ring ( 7 ) from Air Piston ( 6 ).
11. Unscrew Valve Body ( 34 ) from Stop ( 23 ).
• Use a 2-inch socket to secure the Stop.
12. Remove O-Ring ( 33 ) from the Valve Body.
13. Remove O-Ring ( 25 ) from the Stop.
14. Remove Pin ( 24 ) from the Stop as required.
15. Remove Ball ( 29 ), Seat ( 31 ), and Spring Discs ( 32 )
from the Valve Body.
16. Remove O-Ring ( 30 ) from the Seat.
17. Remove upper Nut ( 5 ) that secures Air Piston ( 6 ) to
Rod ( 18 ).
• Remove the Air Piston from the Rod.
NOTE : Place an appropriate size punch or
other suitable tool into the hole of the Rod.
See Figure 2 .
18. Remove O-Ring ( 8 ) and Washer ( 9 ) from the Upper
Rod.
19. Remove the Rod (with attached components) from the
Outlet Body.
20. Remove lower Nut ( 5 ) that secures Fluid Piston ( 20 ) to
the Rod.
NOTE : Place an appropriate size punch or
other suitable tool into the hole of the Rod.
21. Remove Plate ( 22 ), Gasket ( 21 ), and the Fluid Piston
from the Rod.
22. Remove Retaining Ring ( 19 ) from the Rod as needed.
23. Remove Retaining Ring ( 17 ), Washer ( 16 ), Seal ( 15 ),
Lantern Ring ( 14 ), and Seal ( 13 ) from the Outlet Body.
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SER 9616-A Low-Pressure Transfer Pump
Revision (10-98) 6 Alemite Corporation
3. Install O-Rings ( 10 ) onto both ends of the Outlet
Body.
4. Install Retaining Ring ( 19 ) onto Rod ( 18 ).
IMPORTANT: Make sure the ground side of
Plate ( 22 ) contacts Fluid Piston ( 20 ).
5. Install Fluid Piston ( 20 ) [segmented side first], Gasket
( 21 ), and Plate ( 22 ) [ground side first] onto the bottom
of the Rod.
6. Install Nut ( 5 ) that secures the Plate to the Rod.
• Tighten the Nut securely.
• Place an appropriate size punch or other suitable tool
into the hole of the Rod.
CAUTION
Install the Rod assembly into the Body with a
twisting motion. Use care not to damage the Seals.
7. Install the Rod assembly into the bottom of the Outlet
Body.
• Position the Fluid Piston flush with the bottom of the
Body.
8. Install Washer ( 9 ), O-Ring ( 8 ), and Air Piston ( 6 )
(observe THIS SIDE UP] onto the Rod.
9. Install Nut ( 5 ) that secures the Air Piston to the Rod.
• Tighten the Nut securely.
• Place an appropriate size punch or other suitable tool
into the hole of the Rod.
10. Install O-Ring ( 7 ) onto the Air Piston.
11. Screw Stop ( 23 ) into Cylinder ( 26 ) until it seats.
12. Install Pin ( 24 ) into the Stop.
• Make sure the Pin does not protrude from either side
of the Stop.
Clean and Inspect
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 Air Piston ( 6 ) and Fluid Piston ( 20 ) for fatigue
cracks.
• Replace as necessary.
4. Inspect Rod ( 18 ) closely. Use a magnifying glass to
detect any score marks on the Rod.
• Replace as necessary.
5. Closely inspect the mating surfaces of all check valve
components for any imperfections. Ensure a smooth
and clean contact is obtained when assembled.
EXAMPLE : Place Ball ( 29 ) into Seat ( 31 ).
Fill the Seat with solvent. Make sure no
leakage occurs.
Assembly
NOTE : Prior to assembly, certain compo-
nents require lubrication. Refer to Table 3
for details.
Pump Tube Assembly
NOTE : Refer to Figure 4 for a section view
of the pump tube assembly.
Outlet Body
1. Install and seat Seal ( 13 ) [stem end first], Lantern Ring
( 14 ) [stepped end first], Seal ( 15 ) [stem end first], and
Washer ( 16 ) into Outlet Body ( 11 ).
2. Secure the components with Retaining Ring ( 17 ).
• Make sure the Retaining Ring seats properly in the
groove.
Item No. Description Notes Item No. Description Notes
Clean Oil
10 O-Ring, 2-3/4 " ID x 3 " OD (Lower) Pump Tube Portion 25 O-Ring, 1-7/16 " ID x 1-5/8 " OD
13 Seal, 1/2 " ID x 3/4 " OD 30 O-Ring, 1-1/4 " ID x 1-3/8 " OD
15 Seal, 1/2 " ID x 7/8 " OD 33 O-Ring, 1-15/16 " ID x 2-1/8 " OD
Magnalube-G Teflon Grease
7O-Ring, 2-5/8 " ID x 3 " OD 10 O-Ring, 2-3/4 " ID x 3 " OD (Upper) Air Motor Portion
8O-Ring, 3/8 " ID x 1/2 " OD
Coat the Inside Diameter of the Air Motor Assembly
Table 3 Lubricated Components
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Low-Pressure Transfer Pump SER 9616-A
Alemite Corporation 7 Revision (10-98)
25
29
27
21
5
6
7
8
9
11
10
12
13
14
17
15
19
20
22
5
23
33
30
32 31
34
16
10
18
24
26
Weep
Hole
13. Install O-Ring ( 25 ) onto the Stop.
14. Install and seat Spring Discs ( 32 ) in an alternate
pattern into Valve Body ( 34 ).
• See Figure 4 for details.
IMPORTANT: Make sure to press O-Ring
( 30 ) fully into the groove of Seat (31).
15. Install and seat O-Ring (30) into Seat (31).
16. Install the Seat assembly [O-Ring upward] into
the Valve Body.
17. Install Ball (29) into the Seat.
18. Install and seat O-Ring (33) onto the groove of
the valve Body.
19. Screw the Valve Body assembly onto the Stop.
• Tighten the Valve Body securely.
20. Install Air MotorAssembly (4)squarely onto the
Body.
• Use care passing the O-Ring.
• Make sure the outlet of the Body orients
properly with the inlet of the Air Motor.
21. Install the Cylinder assembly squarely onto the
bottom of the Outlet Body.
• Use care passing the O-Ring.
22. Install and seat Ring (27) [counter bore end
first] onto the Cylinder.
• Rotate the Ring until the holes align with the
Air Motor Assembly.
23. Install Screws (28) that secure the Ring to the
Air Motor Assembly.
• Tighten the Screws evenly and securely in a
crisscross pattern.
24. Screw Bushing (12) [with thread sealant] into
the Outlet Body.
• Tighten the Bushing securely.
Air Motor Assembly
25. Screw Shut-Off Valve (3) [with thread sealant]
into the Air Motor Assembly.
• Tighten the Shut-Off Valve securely in the
position required.
26. ScrewAdapter (2) onto the Shut-OffValve [with
thread sealant].
• Tighten the Adapter securely.
27. Install Air Coupler (1) onto the Adapter.
Figure 4 Pump Tube Assembly - Section View
Refer to Figure 2 Parts List
for Parts Identification
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SER 9616-A Low-Pressure Transfer Pump
Revision (10-98) 8 Alemite Corporation
Operation
WARNING
Do not exceed the lowest pressure rating
of any component in the system.
Never point a control valve at any portion of your
body or another person. Lubricant discharged at
high velocity can penetrate the skin and cause
severe injury. Should any fluid 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.
1. Make sure air pressure at the regulator reads zero.
2. Slowly supply air pressure [not to exceed 20 psi
(1.4 Bars] to the pump’s motor.
• The pump assembly should cycle.
If the pump assembly does not cycle, refer to the
Troubleshooting Chart for details.
With air pressure at zero:
3. Connect a product hose to the pump’s material outlet.
• Direct the hose into an appropriate container.
4. Place the pump in the product to be dispensed.
5. Slowly supply air pressure to the pump’s motor.
6. 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.
WARNING
Should leakage occur anywhere within the
system, disconnect air to the motor. Personal
injury can occur.
With air pressure at zero:
7. Attach a control valve to the outlet hose of the pump.
8. Slowly supply 35 psi (2.4 Bars] air pressure to the
pump’s motor.
9. Operate the control valve into a container.
10. Allow the pump to cycle until the system and product
is once again free of air.
11. Shut off the control valve.
12. Set the air pressure to 100 psi (6.9 Bar).
13. Visually inspect the pump for external leaks.
• The pump should not cycle.
If the pump does not stall, refer to the
Troubleshooting Chart for details.
14. Check the motor for air leakage.
If the motor leaks, refer to the Troubleshooting Chart
in the Air Motor Service Guide for details.
Installation
Additional items that should be incorporated into the
air piping systems are listed in Table 4.
Part Number Description
5604-2 Moisture Separator
7604-B Regulator and Gauge
Table 4 Air Line Components
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Low-Pressure Transfer Pump SER 9616-A
Alemite Corporation 9 Revision (10-98)
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 1. Product source empty 1. Replenish product
Pump will not stall (cycles
more than once or twice per
hour)
1. Pump requires break-in period
2. Pump leaking internally
3. Pump leaking externally
4. Distribution system leaking
1. Operate the pump against moderate fluid
pressure for up to one hour
2. See Internal Leaks
3. See External Leaks
4. Correct leak
External Leaks
Product leakage visible at
weep hole in Outlet Body
(11)
1. Damaged Seal (15)
2. Damaged Rod (18)1. Replace Seal (15) 2. Inspect Rod (18) and replace as necessary
Product leakage visible at
bottom of Outlet Body (11)1. Screws (28) not sufficiently tight 2. Damaged O-Ring (10)1. Tighten Screws (28) into Air Motor Assembly (4)
2. Separate Cylinder (26) from Outlet Body
(11) and replace O-Ring (10)
Air leakage at weep hole in
Outlet Body (11)Damaged Seal (13) Replace Seal (13)
Product leakage visible
between Cylinder (26) and
Valve Body (34)
1. Stop (23) not sufficiently tight into
Valve Body (34)
2. Damaged O-Ring (24)
1. Tighten Stop (23) into Valve Body (34)
2. Separate Valve Body (34) from Stop (23)
and replace O-Ring (24)
Internal Leaks
Pump does not prime or
cycles continuously, or
slowly (once or twice/hour)
1. Foreign material between Ball (29)
and Seat (31)
2. Foreign material between Plate (22)
and Fluid Piston (20)
3. Worn or damaged Ball (29)
4. Worn or damaged Seat (31)
5. Worn or damaged O-Ring (7)
6. Worn or damaged Cylinder (26)
7. Worn or damaged Plate (22)
8. Worn or damaged Fluid Piston (20)
Locate and eliminate source of foreign
material.
Disassemble pump tube, clean, inspect, and
replace worn or damaged components
Changes Since Last Printing
Changed Contents of Repair Kit 393627
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SER 9616-A Low-Pressure Transfer Pump
Revision (10-98) 10 Alemite Corporation
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