Alemite 9668 User manual

Service Guide
9668
Alemite Corporation
PO Box 473515, Charlotte, North Carolina 28247-3515
Copyright
©
1997 by Alemite Corporation
This document contains confidential information that is the property of Alemite Corporation
670728
and is not to be copied, used, or disclosed to others without express written permission.
Revision (1-97)
SER 9668
16-1/4 "
(41.3 cm)
Air Exhaust
Air Inlet
Material
Outlet
Material Inlet
Bung
Adapter
5-1/4 "
(13.3 cm)
Figure 1 Medium-Pressure Stub Pump
Model 9668
Description
The major components of the model 9668 stub pump consists of
an air-operated motor and a pump tube. The air motor connects
directly to the double-acting reciprocating pump tube.
This medium-pressure stub pump (5:1 ratio) is designed to
deliver all grades of oil. The pump’s bung adapter [2 " NPTF (m)] *
allows installation directly onto original containers or bulk tanks.
Pump Extensions
Extensions that screw directly into the pump’s material inlet
allow the pump to accommodate different size drums and tanks.
Extensions are accessory items and are not included with the pump.
See Table 2 .
Specifications
Air Motor
Pump Tube
* Certain packages that incorporate this pump do not include
the bung adapter.
Piston Diameter x Stroke Air Inlet
Maximum Air
Pressure
Inches Centimeters psi Bars
2-15/16 x 3 7.5 x 7.6 1/4 " NPTF (f) 150 10.3
For details on the air motor, refer to Service Guide SER 338066-A1
Material
Inlet Material Outlet
Max. Material
Pressure Delivery/Minute (Approximate)* Displacement per Cycle
psi Bars Gallons Liters In
3
Cm
3
1-1/2 " NPTF 1/2 " NPTF 750 52 7 26.5 7.2 118
* For detailed information, refer to Figure 3
Table 1 Medium-Pressure Stub Pump Specifications
Medium-Pressure Stub Pump
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SER 9668 Medium-Pressure Stub Pump
Revision (1-97) 2 Alemite Corporation
E
D
T
H
I
S
S
I
U
P
Weep
Hole
2
3
4
5
6
7
8
9
10
1
19
12
14
15
16
17
18
20
21
23
24
25
26
27
28
13
Apply
Loctite 222
Here
22
11
a
Figure 2 Medium-Pressure Stub Pump Model 9668- Exploded View
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Medium-Pressure Stub Pump SER 9668
Alemite Corporation 3 Revision (1-97)
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
1 Motor Assembly, Air 1 See SER 338066-A1 171000-14 (7)
2 Screw, 3/8 " -24 x 3/4 " 1 171000-103 (4)
3 338111 Piston, Air 1 171003-10 (5)
4 O-Ring, 2-5/8 " ID x 3 " OD 1 171009-31 (26)
5 171003-10 O-Ring, 2-3/4 " ID x 3 " OD 1 171009-51 (19)
6 338089 Body 1 171700-36 (17)
7 171000-14 O-Ring, 3/4 " ID x 15/16 " OD 1 171892 (10)
8 338057 Adapter, Outlet 1 172190-22 (11)
9 Keeper 4 172190-23 (13)
10 Capscrew, 5/16 " -18 x 1/2 " 4 172270-13 (25)
11 Seal, 1-5/16 " ID x 1-9/16 " OD 1 172409 (2)
12 338060 Bearing (Brass) 1 323693 (a)
13 Seal, 1-5/16 " ID x 1-11/16 " OD 1 323707 (18)
14 338059 Spacer 1 323713 (28)
15 338106 Rod 1 323778 (27)
16 338120 Piston (Nylon) 1 326750-B1 (22)
17 Ball, 9/16 " Dia. 1 335481 (24)
18 323707 Seat, Valve 1 335483 (23)
19 O-Ring, 1-7/8 " ID x 2 " OD 1 338041 (9)
20 Ring, Back-Up 1 338057 (8)
21 338090 Tube 1 338059 (14)
22 326750-B1 Adapter, Bung, 2 " NPTF (m) 1 338060 (12)
23 Washer, 1-1/8 " OD 1 338066-A1 (1)
24 Spring, Tapered 1 338089 (6)
25 172270-13 Ball, 1-1/16 " Dia 1 338090 (21)
26 171009-31 O-Ring, 1-11/16 " ID x 1-7/8 " OD 1 338091 (20)
27 323778 Valve, Foot 1 338106 (15)
28 323713 Pin, 1/4 " Dia. x 1-25/32 " Long 1 338111 (3)
Kit Component for Early Model Pumps 338120 (16)
a 323693 Gasket (Aluminum) 1
Legend :
Part numbers left blank (or in italics ) are not available separately
designates a repair kit item
Repair Kits
Part No. Kit Symbol Description
393571-1 Kit, Repair (for Upper Pump Tube Assembly) [Includes tube of 393590 Teflon Grease]
393572 Kit, Repair (for Lower Pump Tube Assembly)
393641 Kit, Repair, Air Motor Keeper and Screw
393530-22 Kit, Seal [includes five (5) of item number 11 ]
393530-23 Kit, Seal [includes five (5) of item number 13 ]
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SER 9668 Medium-Pressure Stub Pump
Revision (1-97) 4 Alemite Corporation
Accessories
Extensions for various size containers are indicated below.
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 200/205 liter 250-Gallon
Bench-Top 275-Gallon Obround
V-Cut 338147-1 338147-2 338147-3 338147-7
Threaded at both ends * 338246-1 338246-2 338246-3 338246-6
* NOTE : For use with low level cut-off valve part number 321206
Table 2 Medium-Pressure Stub Pump Model 9668 Accessories
700
SAE No. 10W -40 at 77 F (25 C)
600
500
400
300
200
100
001 2 34 5 6 7
800
5
10
15
20
25
30
35
0
40
100 psi (6.9 Bars)
150 psi (10.3 Bars) 150 psi (10.3 Bars)
50 psi (3.4 Bars)
50 psi (3.4 Bars)
Legend:
Air Pressure
Material Discharge Pressure
Air Consumption
Gallons per Minute
Liters per Minute
Delivery
510 15 20 25
100
200
300
400
500
600
700
800
900
Air Consumption
lpm
cfm
psi
1000
1100
Bars
Material Discharge Pressure (psi)
5
10
15
20
25
30
35
40
45
50
55
100 psi (6.9 Bars)
Figure 3 Delivery versus Discharge Pressure and Air Consumption
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Medium-Pressure Stub Pump SER 9668
Alemite Corporation 5 Revision (1-97)
Damage to Components can Occur
Damage to Seals can Occur
Service Hints
Refer to the Overhaul Procedures for Details
Inspect the Chamfer of the Rod for Roughness
Make Sure to Align the Hole in the Spacer
with the Outlet Hole in the Body
Apply Loctite 222 to the Threads of the Valve Seat
Valve Seat may Loosen
Do not Overtighten the Valve Seat into the Rod
Distortion of Nylon Piston can Occur
Ensure Rings are not Exposed After Tube Installation
Product Leakage can Occur
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SER 9668 Medium-Pressure Stub Pump
Revision (1-97) 6 Alemite Corporation
Overhaul
NOTE : Refer to Figures 2 and 3 for compo-
nent identification on all overhaul proce-
dures.
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
when aluminum and/or zinc-plated parts in the
pump come in contact with halogenated hydrocar-
bon 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 at
Bung Adapter ( 22 ).
2. Remove Capscrews ( 10 ) that secure Body ( 6 ) to the
Air Motor assembly.
• Remove Keepers ( 9 ) from the Body.
3. With a side-to-side motion, pull Air Motor
Assembly ( 1 ) from the Body.
• Lubricate O-Ring ( 5 ) with oil to ease separation.
Pump Tube
4. Remove O-Ring ( 5 ) from the Body.
5. Unscrew Adapter ( 8 ) from the Body.
6. Remove O-Ring ( 7 ) from the Adapter.
7. Unscrew Tube ( 21 ) [with Bung Adapter ( 22 )] from the
Body.
• Remove the Bung Adapter from the Tube as required.
8. Remove O-Ring ( 19 ) and Back-Up Ring ( 20 ) from the
Tube.
9. Remove Screw ( 2 ) that secures Air Piston ( 3 ) to
Rod ( 15 ).
• Remove the Air Piston from the Rod.
10. Remove O-Ring ( 4 ) from the Air Piston.
11. Pull the Rod assembly from the bottom of the Body.
12. Unscrew Valve Seat ( 18 ) from the Rod.
• Remove Ball ( 17 ) and Nylon Piston ( 16 ).
13. Remove Spacer ( 14 ) and Seal ( 13 ) from the Body.
14. Remove Bearing ( 12 ) and Seal ( 11 ) from the Body.
Foot Valve Assembly
15. Unscrew Foot Valve ( 27 ) from Tube ( 21 ).
16. Remove O-Ring ( 26 ) from the Foot Valve.
17. Remove Pin ( 28 ) from the Foot Valve.
18. Remove Washer ( 23 ), Spring ( 24 ), and Ball ( 25 ) from
the Foot Valve.
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 cleaning solvent. The solvent
should be environmentally safe.
2. Inspect all parts for wear and/or damage.
• Replace as necessary.
3. Inspect Air Piston ( 3 ) for fatigue cracks.
• Replace as necessary.
4. Inspect Nylon Piston ( 16 ) and Rod ( 15 ) 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 ( 25 ) into Foot Valve
( 27 ). Fill the Foot Valve with solvent. Make
sure no leakage occurs.
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Medium-Pressure Stub Pump SER 9668
Alemite Corporation 7 Revision (1-97)
Pump Tube and Rod
11. Install and seat Nylon Piston ( 16 ) [openings upward]
onto the bottom of Rod ( 15 ).
12. Install Ball ( 17 ) into the Rod.
IMPORTANT: Do not tighten the Valve Seat
more than 1/4-turn once it contacts the Ny-
lon Piston. Distortion of the Nylon Piston
can occur which causes excessive drag on
the Tube.
13. ScrewValve Seat ( 18 ) [with Loctite 222] into the Rod.
See Figure 2.
• Follow the thread sealant manufacturer’s
recommendations.
CAUTION
Install the Rod into the Body with a twisting
motion. Use care not to damage the Seals.
14. Install the Rod assembly into the bottom of the Body.
• Position the Nylon Piston flush with the bottom of
the Body.
15. Install Back-Up Ring ( 20 ) [concave upward] onto
Tube ( 21 ).
16. Install O-Ring ( 19 ) on top of the Back-Up Ring.
17. Screw and seat the Tube assembly into the Body.
• Make sure both Rings are not visible.
18. Slide Bung Adapter ( 22 ) onto the Tube.
19. Screw the Foot Valve assembly into the Tube.
• Tighten the Foot Valve assembly securely to the
Tube and the Tube to the Body.
Assembly
NOTE : Prior to assembly, certain compo-
nents require lubrication. Refer to Table 3
for details.
Foot Valve
NOTE : Refer to Figure 4 for a section view
of the pump tube assembly.
1. Install O-Ring ( 26 ) onto Foot Valve ( 27 ).
2. Install Ball ( 25 ), Spring ( 24 ) [small diameter first], and
Washer ( 23 ) into the Foot Valve.
3. Install Pin ( 28 ) into the Foot Valve.
• Make sure the Pin retains the Washer properly and is
flush with the Foot Valve.
Pump Tube Body
4. Install O-Ring ( 5 ) onto the upper groove of Body ( 6 ).
5. Install and seat Seal ( 11 ) [heel end first] into the
bottom of the Body.
6. Install and seat Bearing ( 12 ) [small diameter first] into
the Body.
7. Install and seat Seal ( 13 ) [heel end first] into the Body.
CAUTION
Make sure the hole in the Spacer aligns with the
hole in the Body. Damage to components can
occur.
8. Install Spacer ( 14 ) [small diameter first] into the Body.
9. Install O-Ring ( 7 ) onto Adapter ( 8 ).
10. Screw the Adapter into the Body.
• Tighten the Adapter securely.
Item No.
on Figure 2 Description Item No. on Figure 2 Description
Clean Oil
4 O-Ring, 2-5/8 " ID x 3 " OD 13 Seal, 1-5/16 " ID x 1-11/16 " OD
5 O-Ring, 2-3/4 " ID x 3 " OD 19 O-Ring, 1-7/8 " ID x 2 " OD
7 O-Ring, 3/4 " ID x 15/16 " OD 26 O-Ring, 1-11/16 " ID x 1-7/8 " OD
11 Seal, 1-5/16 " ID x 1-9/16 " OD
Magnalube-G Teflon Grease
Coat the Inside Diameter of the Air Motor Assembly
Table 3 Lubricated Components
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SER 9668 Medium-Pressure Stub Pump
Revision (1-97) 8 Alemite Corporation
19
2
4
3
5
6
10 9
7
8
11
13
12
14
15
16
17
18
20
21
23
24
25
26
27
28
B
Detail B
A
Detail A
Lower Seal
Weep Hole
Air Piston
20. Install O-Ring ( 4 ) onto Air Piston ( 3 ).
21. Place theAir Piston (observe THIS SIDE UP) on top of
the Rod.
22. Install Screw ( 2 ) that secures the Air Piston to the Rod.
• Tighten the Screw securely.
Attach Air Motor to Pump Tube
23. Clamp the Body securely in a soft-jaw vise.
24. Install Air Motor Assembly (1) squarely onto the Body.
• Use care passing the O-Ring.
• Make sure Outlet Adapter (8) orients properly with
the inlet of the Air Motor.
25. Install Keepers (9) into the groove of the Body.
• Make sure the holes align with the Air Motor
Assembly.
26. Install Capscrews (10) that secure the Body to the Air
Motor Assembly.
• Tighten the Capscrews evenly and securely in a
crisscross pattern.
Bench Test and Operation
1. Slowly supply air pressure [not to exceed 15 psi
(1 Bar)] 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:
2. Connect a product hose to the pump’s material outlet.
• Direct the hose into an appropriate collection
container.
3. Place the pump in oil.
4. Slowly supply air pressure to the pump’s motor.
5. Allow the pump to cycle slowly until the oil is free of
air.
If the pump assembly does not prime, refer to the
Troubleshooting Chart for details.
Figure 4 Pump Tube Assembly 338067-B - Section View
Refer to Figure 2 Parts List
for Parts Identification
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Medium-Pressure Stub Pump SER 9668
Alemite Corporation 9 Revision (1-97)
WARNING
Should leakage occur anywhere within the
system, disconnect air to the motor. Personal
injury can occur.
With air pressure at zero:
6. Attach a control valve to the outlet hose of the pump.
• Make sure the nozzle on the control valve is open.
7. Slowly supply air pressure to the pump’s motor.
8. Allow the pump to cycle slowly until the oil is once
again free of air.
9. Set the air pressure to the normal operating pressure.
10. Operate the control valve into a container.
11. Shut off the control valve.
• Visually inspect the pump for external leaks.
• The pump should not cycle more than once or twice
in one hour.
If the pump does not stall, refer to the
Troubleshooting Chart for details.
12. Check the motor for air leakage.
If the motor leaks, refer to 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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SER 9668 Medium-Pressure Stub Pump
Revision (1-97) 10 Alemite Corporation
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
3. Extension not sufficiently tight and/or
thread sealant missing or inadequate
1. Reduce air pressure
2. See Internal Leaks
3.Apply thread sealant* to male pipe threads
and tighten extension
Pump cycles rapidly 1. Product source empty
2. Extension not sufficiently tight and/or
thread sealant missing or inadequate
1. Replenish product
2.Apply thread sealant* to male pipe threads
and tighten extension
Pump will not stall (cycles
more than once or twice/hour) 1. Pump requires break-in period
2. Pump leaking internally
3. Pump leaking externally
4. Distribution system leaking
5. Extension not sufficiently tight and/or
thread sealant missing or inadequate
1. Operate the pump against moderate fluid
pressure for up to one hour
2. See Internal Leaks
3. See External Leaks
4. Correct leak
5.Apply thread sealant* to male pipe threads
and tighten extension
External Leaks
Product leakage visible at
weep hole in Body (6)1. Damaged Seal (13) 2. Damaged Rod (15)1. Replace Seal (13) 2. Inspect Rod (15) and replace as necessary
Product leakage visible at
bottom of Body (6)1. Tube (21) not sufficiently tight 2. Damaged O-Ring (17)1. Tighten Tube (21) into Body (6) 2. Separate Tube (21) from Body (6) and
replace O-Ring (19)
Air leakage at weep hole in
Body (6)Damaged Seal (11) Replace Seal (11)
Product leakage visible
between Tube (21) and Foot
Valve (27)
1. Foot Valve (27) not sufficiently tight
2. Damaged O-Ring (26)1. Tighten Foot Valve (27) into Tube (21) 2. Separate Foot Valve (27) from Tube (21)
and replace O-Ring (26)
Internal Leaks
Pump does not prime or
cycles continuously, or slowly
(once or twice/hour)
1. Foreign material between Ball (17)
and Valve Seat (18)
2. Foreign material between Ball (25)
and Foot Valve (27)
3. Worn or damaged Ball (17)
4. Worn or damaged Valve Seat (18)
5. Worn or damaged Ball (25)
6. Worn or damaged Foot Valve (27)
7. Worn or damaged Nylon Piston (16)
Locate and eliminate source of foreign
material
Disassemble pump tube, clean, inspect, and
replace worn or damaged components
* Do not apply thread sealant to the first two (2) threads. Contamination can occur.
Changes Since Last Printing
New Format
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