Alemite 9930 User manual

Service Guide 9930
9979
9979-M
Alemite, LLC
167 Roweland Drive, Johnson City, Tennessee 37601
www.alemite.com
Copyright © 2010 by Alemite, LLC
This document contains confidential information that is the property of Alemite, LLC
670796 and is not to be copied, used, or disclosed to others without express written permission. Revision (8-10)
SER 9930
Figure 1 Pump Model 9930 and 9979 Series
Model 9979-M Shown
Description
The major components of model 9930 and 9979 series grease
pumps consist of an air-operated motor and a pump tube. The air
motor connects directly to the double-acting reciprocating pump
tube.
The pump tube on these high-pressure pumps (50:1 ratio)
feature a dynamic primer (see Figure 2-B) that enables the
delivery of a range of greases.
Mounting
Models 9979 and 9979-M * are stripped pumps that mount
directly to an original 400-pound (180 kg) container with the use
of a cover that:
• utilizes a 2 " NPTF bung adapter
• bolts directly to the body of the pump
Pump model 9930 includes the male portion of a 3-inch
camlock connection for installation onto bulk grease tanks.
* Model 9979-M contains components (See Table 1)
manufactured with BSPT thread connections that include:
• air motor model 339413-A1
• a material outlet adapter in the pump tube’s body
Specifications
Air Motor
Pump Tube
Air Motor
Model Piston Dia. x Stroke Air Inlet Maximum Air
Pressure
in. cm psi bar
339413 3 x 3-5/16 7.6 x 8.4 1/4 " NPTF (f) 150 10.3
339413-A1 1/4 " BSPT (f)
For details on the air motors, refer to Service Guide SER 339413
Pump
Model Material Outlet in Body
Max.
Material
Pressure Delivery/Min.
(Approximate)* Displacement per Cycle
psi bar lbs. kg in 3cm 3
9930, 9979 3/8 " NPTF (f) 7500 517 4.7 2.1 0.76 12.5
9979-M 3/8 " NPTF (f) **
* For detailed information, refer to Figure 3
** Includes a 3/8 " BSPT (f) x 3/8 " NPTF (m) material outlet adapter
Table 1 High-Pressure Grease Pump Specifications
High-Pressure Grease Pump
Pump
Model Camlock Adapter X
In. Cm In. Cm
9930 Included 23 58.4 Y11-3/4 29.8
9979 Not Included 44 111.6 Y134-1/4 87
9979-M *
* With BSPT Thread Connection Components (See Table 1)

SER 9930 High-Pressure Grease Pump
Revision (8-10) 2 Alemite, LLC
Figure 2-A High-Pressure Grease Pump Model 9930 and 9979 Series - Exploded View (Sheet 1 of 2)

High-Pressure Grease Pump SER 9930
Alemite, LLC 3 Revision (8-10)
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
1 Motor Assembly, Air * 1 See SER 339413 11505 (20)
1a 340053 Cover (w/o Decals) 1
Included w/
Motor Assembly
14536 (3)
1b Screw, Cap, 1/4 " -20 x 6-1/2 " 1 X171000-7 (6)
1c Bolt, Carriage, 1/4 " -20 x 7-1/2 " 4 X171003-10 (8)
1d Nut, Serrated Flange, 1/4 " -20 4 X171008-37 (5)
2 339513 Nut, Flange, 3/8 " -24 1 X171009-45(17)
3 Washer, 3/8 " ID x 7/8 " OD 1 172190-24 (12)
4 339429 Piston, Air 1 172190-26 (14)
5 X171008-37 Quad-Ring, 2-5/8 " ID x 3 " OD 1 Pack of Ten (10) 172207-1 (19)
6 X171000-7 O-Ring, 3/8 " ID x 1/2 " OD 1 338072 (13)
7 339109 Washer, 3/8 " ID x 3/4 " OD 1 338073 (15)
8 X171003-10 O-Ring, 2-3/4 " ID x 3 " OD 1 Pack of Ten (10) 338074 (16)
9 338509 Rod 1 338083 (10)
10 Body 1 338109 (7)
11 339412 Keeper 4 338509 (9)
12 Seal, 1/2 " ID x 3/4 " OD 1 338513-2 (21)
13 Ring, Lantern (Brass) 1 338615 (18)
14 Seal, 1/2 " ID x 7/8 " OD 1 339375 (1d)
15 Bearing (Brass) 1 339412 (11)
16 Gasket (Aluminum) 1 339413 (1)
17 X171009-45 O-Ring, 2-9/16 " ID x 2-3/4 " OD 1 Pack of Ten (10)
Model 9930
339413-A1 (1)
339425 (1c)
18 338615 Adapter, Male Camlock 1
Model 9930
339429 (4)
19 Washer, Lock, 1/4 " 3 339513 (2)
20 Screw, 1/4 " -20 x 2-1/2 " 3 340027 (1b)
21 338513-2 Adapter, 3/8 " BSPT (f) x 3/8 " NPTF (m) 1 Model 9979-M 340053 (1a)
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 Notes
393709 Kit, Major Repair [Includes tube of 393590 Teflon Grease] Contains items on
Figures 2-A and 2-B
393708 Kit, Repair, Air Motor Keeper
393530-24 Kit, Seal [includes five (5) of item number 12]
393530-26 Kit, Seal [includes five (5) of item number 14]

SER 9930 High-Pressure Grease Pump
Revision (8-10) 4 Alemite, LLC
Figure 2-B High-Pressure Grease Pump Model 9930 and 9979 Series - Exploded View (Sheet 2 of 2)

High-Pressure Grease Pump SER 9930
Alemite, LLC 5 Revision (8-10)
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
22 338508-3 Tube, Upper, 5.8 " Long 1 Model 9930 171031-5 (29)
338508-2 Tube, Upper, 26.3 " Long 1
Model 9979
171032-3 (40)
23 338055-2 Extension 1 171032-6 (24)
24 171032-6 Pin, Roll, 3/32 " Dia. x 5/8 " Long 2171700-18 (27)
1 Model 9930 172190-10 (35)
25 Guide, Spring 1 172190-25 (31)
26 Spring 1 338055-2 (23)
27 Ball 1 338056 (34)
28 338084 Piston 1 338069 (41)
29 Pin, Roll, 5/64 " Dia. x 1/2 " Long 1 338070 (37)
30 Bearing (Brass) 2 338071 (36)
31 Seal, 5/8 " ID x 1 " OD 1 338075 (38)
32 Gasket (Aluminum) 3 338077 (32)
33 338085 Tube, Lower 1 338078 (39)
34 Stop 1 338079 (26)
35 Seal, 0.282 " ID x 0.532 " OD 1 338080 (25)
36 338071 Valve, Foot 1 338081 (30)
37 338070 Seat 1 338084 (28)
38 338075 Rod, Primer 1 338085 (33)
39 Disk, Primer 1 338508-2 (22)
40 Pin, Roll, 3/32 " Dia. x 3/8 " Long 1 1338508-3 (22)
41 338069 Body, Primer 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 Notes
393709 Kit, Major Repair (Includes tube of 393590 Teflon Grease) Contains items on
Figures 2-B and 2-A
393530-10 Kit, Seal [includes five (5) of item number 34]
393530-25 Kit, Seal [includes five (5) of item number 30]

SER 9930 High-Pressure Grease Pump
Revision (8-10) 6 Alemite, LLC
Accessories
Performance Curves
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 pounds (kilograms) 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).
Model Number Container Size Follower Cover Bung Adapter
9930 Equipped with a Camlock Adapter for Bulk Tank Installation
9979 400 lbs 338911
338165
318040-4 * 326750
9979-M 180 kg 338984* 326750
* These Covers are designed to be used with a Bung Adapter.
Table 2 High-Pressure Grease Pump Accessories
Figure 3 Delivery versus Discharge Pressure and Air Consumption

High-Pressure Grease Pump SER 9930
Alemite, LLC 7 Revision (8-10)
Overhaul
NOTE: Refer to Figures 2-A and 2-B 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
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
Body (10).
2. Remove Cover (1a).
• Pry and swing the Cover sideways away from the
Cylinder.
•RefertoSER339413 for details.
3. Remove Screw (1b) from the Top Cap.
4. Remove Nuts (1d) that secure the Body to Air Motor
Assembly (1).
5. Remove Carriage Bolts (1c) from the Top Cap.
• Remove Keepers (11) from the Body.
6. Remove the Top Cap from the Cylinder.
CAUTION
Remove the Cylinder with care. Damage to Quad-
Ring (5) and/or O-Ring (8) can occur.
7. With a side-to-side motion, pull the Cylinder from the
Body and Air Piston (4).
8. Remove O-Ring (8) from the Body.
9. Remove the Bottom Cap from the Body.
Pump Tube Assembly
Air Piston
10.Remove Nut (2) and Washer (3) that secures Air Pis-
ton (4) to Rod (9).
• Place a punch or similar tool into the Rod to prevent
its rotation. See Figure 2-A.
• Remove the Air Piston from the Rod.
11.Remove Quad-Ring (5) from the Air Piston.
12.Remove O-Ring (6) and Washer (7) from the Rod.
Body Assembly
13.Remove O-Ring (8) from the Body.
Step for Model 9930 Only
14. Remove Screws (20) Lock Washers (19) that secure
Camlock Adapter (18) to the Body.
• Remove the Camlock Adapter from the Body.
• Remove O-Ring (17) from the Camlock Adapter.
15. Unscrew Upper Tube (22) from the Body.
16. Remove the Body assembly from the Rod.
17. From inside the Body remove:
•Gasket(16)
• Bearing (15)
•Seal(14)
• Lantern Ring (13)
•Seal(12)
Step for Model 9979-M Only
18. Unscrew Adapter (21) from the Body only when
necessary.
• Adapter is secured with Loctite 242.
Tube Assembly
19. Push the Rod assembly downward through Upper Tube
(22) until Primer Disk (39) protrudes from Primer
Body (41).

SER 9930 High-Pressure Grease Pump
Revision (8-10) 8 Alemite, LLC
Primer Body
29. Unscrew Primer Body (41) from the Lower Tube.
30. From inside the Lower Tube remove:
•Gasket(32)
• Seat (37)
• additional Gasket (32)
• Foot Valve (36) [with Seal (35)]
• Stop (34)
31. Remove the Seal from the Foot Valve.
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 (4) for fatigue cracks.
• Replace as necessary.
4. Inspect Rod (9), Piston (28), and Primer Rod (38)
closely. Use a magnifying glass to detect any score
marks.
• 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 (27) into Piston (28).
Fill the Piston with solvent. Make sure no
leakage occurs.
Assembly
NOTE: Prior to assembly, certain compo-
nents require lubrication. Refer to Table 3
for details.
20. Remove Roll Pin (40) that secures the Primer Disk to
Primer Rod (38).
• Remove the Primer Disk from the Primer Rod.
21. Remove the entire Rod assembly from the top of the
Upper Tube.
22. Remove Roll Pin (29) that secures the Primer Rod to
Piston (28).
• Unscrew the Primer Rod from the Piston.
Step for Model 9979 Only
23. Remove Roll Pin (24) that secures Extension (23) to
the Piston.
• Unscrew the Piston from the Extension.
Step for Model 9979 Only
24. Remove Roll Pin (24) that secures Rod (9) to the
Extension.
• Unscrew the Extension from the Rod.
Step for Model 9930 Only
25. Remove Roll Pin (24) that secures Rod (9) to the
Piston.
• Unscrew the Piston from the Rod.
26. From inside the Piston remove:
• Spring Guide (25)
• Spring (26)
• Ball (27)
27. Unscrew the Upper Tube from Lower Tube (33).
• Use a strap wrench.
Lower Tube
28. Remove Gasket (32), Bearing (30), Seal (31), and
additional Bearing (30) from the Lower Tube.
Item No. Description Item No. Description
Clean Oil
5 Quad-Ring, 2-5/8 " ID x 3 " OD 14 Seal, 1/2 " ID x 7/8 " OD
6 O-Ring, 3/8 " ID x 1/2 " OD 17 O-Ring, 2-9/16 " ID x 2-3/4 " OD
8 O-Ring, 2-3/4 " ID x 3 " OD 31 Seal, 5/8 " ID x 1 " OD
12 Seal, 1/2 " ID x 3/4 " OD 35 Seal, 0.282 " ID x 0.532 " OD
Magnalube-G Teflon Grease *
Coat the Bore of the Air Motor Assembly
* Part number 393590 is a 0.75 ounce (21.8 gm) tube of Magnalube-G Teflon grease
Table 3 Lubricated Components

High-Pressure Grease Pump SER 9930
Alemite, LLC 9 Revision (8-10)
Pump Tube Assembly
1. Install and seat Seal (12) [heel end
first] into the bottom of the Body.
2. Install and seat Lantern Ring (13)
[small diameter end first] into the
Body.
3. Install and seat Seal (14) [heel end
first] into the Body.
4. Install and seat Bearing (15) [small
diameter end first] into the Body.
5. Install and seat Gasket (16) into the
Body.
Steps for Model 9979 Only
6. Screw Rod (9) into Extension (23)
until the Pin holes align.
• Secure the Extension to the Rod
with Roll Pin (24).
7. Install Ball (27), Spring (26), and
Spring Guide (25) [pointed end first]
into Piston (28).
Step for Model 9979 Only
8. Screw the Piston assembly onto the
Extension until the Pin holes align.
• Secure the Piston to the Extension
with Roll Pin (24).
Step for Model 9930 Only
9. Screw the Piston assembly onto the
Rod until the Pin holes align.
• Secure the Piston to the Rod with
Roll Pin (24).
10. Screw Primer Rod (38) into the Piston
assembly until the Pin holes align.
• Secure the Piston assembly to the
Primer Rod with Roll Pin (29).
11. Install and seat Bearing (30), Seal
(31) [heel end first], and additional
Bearing (30) into the externally
threaded end of Lower Tube (33).
12. Install and seat Gasket (32) into the
internally threaded end of Lower
Tube (22).
Figure 4 Pump Tube Assembly 338086-A1 and -C1 - Section View
Refer to Figures 2-A and 2-B Parts List
for Parts Identification

SER 9930 High-Pressure Grease Pump
Revision (8-10) 10 Alemite, LLC
IMPORTANT: If a primer is used with Loc-
tite 222, the curing time is greatly reduced.
13. Screw the Lower Tube [with Loctite 222] into the
Upper Tube.
• Follow the thread sealant manufacturer’s
recommendations.
• Do not tighten at this time.
14. Install the Rod assembly into the Upper Tube until it
protrudes from the Lower Tube.
• Use care not to damage the Seal.
15. Install Seal (35) [heel end first] into Foot Valve (36).
16. Install Stop (34), the Foot Valve assembly [Seal end
first], Gasket (32), Seat (37) [small diameter end
first], and additional Gasket (32) over the Primer Rod
and into the Lower Tube.
17. Install Primer Disk (39) onto the Primer Rod.
• Make sure the hole align.
18. Install Roll Pin (40) that secures the Primer Disk to
the Primer Rod.
19. Screw Primer Body (41) [with Loctite 222] into the
Lower Tube.
• Follow the thread sealant manufacturer’s
recommendations.
• Do not tighten at this time.
CAUTION
Install the Rod and Tube assembly into the Body
with a twisting motion. Use care not to damage
the Seals.
20. Install the Rod and Tube assembly into the Body and
at the same time screw the Upper Tube [with Loctite
222] into the Body.
• Follow the thread sealant manufacturer’s
recommendations.
21. Tighten all the threaded pump tube components into
one another.
• Place a bar or other suitable tool in the holes of the
Primer Body for leverage.
• Tighten sufficiently to properly crush all Gaskets.
22. Install O-Ring (8) onto the upper groove of Body (10).
Step for Model 9979-M Only
23. Screw Adapter (21) [with Loctite 242] into the Body
as required.
Air Piston
CAUTION
Use care not to switch Washers (3 and 7). Compo-
nent damage can occur.
24. Install Washer (7) [brass color] and O-Ring (6) onto the
Rod.
25. Install Quad-Ring (5) onto Air Piston (4).
26. Place the Air Piston (observe THIS SIDE UP) on top of
the Rod.
27. Install Washer (3) [silver color] and Nut (2) that
secures the Air Piston to the Rod.
• Tighten the Nut securely.
NOTE: Place an appropriate size punch or
other suitable tool into the hole of the Rod.
See Figure 2-A.
Model 9930 Only
28. Install and seat O-Ring (17) into the groove of Camlock
Adapter (18).
29. Install the Camlock Adapter onto the pump tube.
• Make sure the Screw holes align.
30. Install Lock Washers (19) and Screws (20) that secure
the Camlock Adapter to the Body.
• Tighten the Screws securely.
Attach Air Motor to Pump Tube
1. Clamp the pump at the flats of Body (10) securely in a
soft-jaw vise.
2. Install the Bottom Cap onto the Body.
3. Install O-Ring (8) onto the upper groove of the Body.
CAUTION
Install the Cylinder with care. Damage to Quad-
Ring (5) and/or O-Ring (8) can occur.
HINT: Angle the Cylinder onto the Quad-
Ring.
4. Install the Cylinder over the Body’s O-Ring and seat it
properly onto the Bottom Cap.

High-Pressure Grease Pump SER 9930
Alemite, LLC 11 Revision (8-10)
5. Install the Top Cap onto the Cylinder.
• Use care passing the O-Ring.
6. Install Keeper (11) into the groove of the Body.
• Make sure the hole aligns with Carriage Bolt (1c).
7. Install one Carriage Bolt through the Air Motor and
through the Keeper.
8. Install Flange Nut (1d).
• Do not tighten the Flange Nut at this time.
9. Repeat procedural steps 34 - 36 for the additional
Carriage Bolts and Keepers.
CAUTION
Do not overtighten Flange Nuts (1d). Component
damage can occur.
10. Torque each Flange Nut in an alternate pattern from 60
to 70 inch-pounds (6.8 - 7.9 Nm).
11. Install Screw (1b) into the Top Cap.
• Tighten the Screw to 50 inch-pounds (5.6 Nm).
12. "Snap" Cover (1a) onto the Cylinder.
Bench Test and Operation
1. Install the required hardware to the Air Motor
Assembly to accept an air line.
2. Slowly supply air pressure [recommended minimum of
25 psi (1.7 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 collection
container.
4. Place the pump in grease.
5. Slowly supply air pressure to the pump’s motor.
6. Allow the pump to cycle slowly until the grease 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.
• Make sure the nozzle on the control valve is open.
8. Slowly supply air pressure to the pump’s motor.
9. Allow the pump to cycle slowly until the grease is
once again free of air.
10. Set the air pressure to the normal operating pressure.
11. Operate the control valve into a container.
12. 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.
13. 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

SER 9930 High-Pressure Grease Pump
Revision (8-10) 12 Alemite, LLC
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 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
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 Body (10)1. Damaged Seal (14) 2. Damaged Rod (9)1. Replace Seal (14) 2. Inspect Rod (9) and replace as
necessary
Product leakage visible at
bottom of Body (10)1. Upper Tube (22) not sufficiently tight
2. Damaged Gasket (16)
1. Tighten Upper Tube (22) into Body
(10)
2. Replace Gasket (16)
Air leakage at weep hole in
Body (10)1. Damaged Seal (12) 2. Damaged Rod (9)1. Replace Seal (12) 2. Inspect Rod (9)
Product leakage visible at
weep hole in Upper Tube
(22)
1. Lower Tube (33) not sufficiently tight
2. Damaged Gasket (32)
1. Tighten Lower Tube (33) into Upper
Tube (22)
2. Replace Gasket (32)
Product leakage visible at
weep hole in Lower Tube
(33)
1. Primer Body (41) not sufficiently tight
2. Damaged Gasket(s) (32)
1. Tighten Primer Body (41) into Lower
Tube (33)
2. Replace Gasket(s) (32)
Internal Leaks
Pump does not prime or
cycles continuously, or
slowly (once or twice/hour)
1. Foreign material between Ball (27) and
Piston (32)
2. Foreign material between Foot Valve (36)
and Seat (37)
3. Worn or damaged Ball (27)
4. Worn or damaged Piston (32)
5. Worn or damaged Foot Valve (36)
6. Worn or damaged Seat (37)
7. Worn or damaged Seal (31)
8. Worn or damaged Seal (35)
9. Worn or damaged Primer Rod (38)
Locate and eliminate source of foreign
material
Disassemble pump tube, clean, inspect,
and replace worn or damaged
components
Changes Since Last Printing
Added items 25 and 39 to Repair Kit. These items no longer available separately.