Alemite 9968 User manual

Service Guide
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
670789 and is not to be copied, used, or disclosed to others without express written permission. Revision (8-10)
SER 9968
9968
9968-A
9968-M
Figure 1 Stub Pump Model 9968 Series
Model 9968-M Shown
Description
The major components of the stub pumps in the model 9968
series consists of an air-operated motor and a pump tube. The air
motor connects directly to a double-acting reciprocating pump
tube. These low-pressure stub pumps (5:1 ratio) are designed to
deliver all grades of oil.
Pump Extensions
Extensions that screw directly into the pump’s fluid 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.
Models 9968 Series Comparison
Model 9968 and 9968-M * include a 2 " NPTF (m) bung
adapter that allows installation directly onto original containers or
bulk tanks. The bung adapter is not included with model 9968-A.
* Model 9968-M contains components (See Table 1)
manufactured with BSPT(P) thread connections that include:
• air motor model 339413-A1
• a fluid 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 Fluid Outlet in Body
Max.
Fluid
Pressure Delivery/Min.
(Approximate)* Displacement per Cycle
psi bar gals liters in 3cm 3
9968, 9968-A 1/2 " NPTF (f) 750 52 7 26.5 7.2 118
9968-M 1/2 " NPTF (f) **
* For detailed information, refer to Figure 3
** Includes a 1/2 " BSPP (f) x 1/2 " NPTF (m) fluid outlet adapter
Table 1 Low-Pressure Stub Pump Specifications
Low-Pressure Stub Pump
Pump Model Bung Adapter
9968 Included
9968-A Not Included
9968-M * Included
* With BSPT(P) Thread Connection Components (See Table 1)

SER 9968 Low-Pressure Stub Pump
Revision (8-10) 2 Alemite, LLC
Figure 2 Low-Pressure Stub Pump Model 9968 Series - Exploded View

Low-Pressure Stub Pump SER 9968
Alemite, LLC 3 Revision (8-10)
Repair Kits
Part No. Kit Symbol Description
393715 Kit, Repair (Includes tube of 393590 Teflon lubricant)
393708 Kit, Repair, Air Motor Keeper
393530-22 Kit, Seal [includes five (5) of item number 10]
393530-23 Kit, Seal [includes five (5) of item number 12]
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
1 Motor Assembly, Air * 1 See SER 339413 14536 (3)
1a 340053 Cover (w/o Decals) 1
Included w/
Motor Assembly
X171000-7 (5)
1b Screw, Cap, 1/4 " -20 x 6-1/2 " 1 X171003-10 (7)
1c Bolt, Carriage, 1/4 " -20 x 7-1/2 " 4 X171008-37 (6)
1d Nut, Serrated Flange, 1/4 " -20 4 171009-31 (27)
2 Screw, 3/8 " -24 x 3/4 " 1 171009-51 (19)
3 Washer, 3/8 " 1 171700-36 (17)
4 339429 Piston, Air 1 172190-22 (10)
5 X171000-7 O-Ring, 3/8 " ID x 1/2 " OD 1
Pack of Ten (10)
172190-23 (14)
6 X171008-37 Quad-Ring, 2-5/8 " ID x 3 " OD 1 172270-13 (25)
7 X171003-10 O-Ring, 2-3/4 " ID x 3 " OD 1 172409 (2)
8 Body 1 323693 (x)
9 339412 Keeper 4 323707 (18)
10 Seal, 1-5/16 " ID x 1-9/16 " OD 1 323713 (28)
11 338060 Bearing (Brass) 1 323778 (27)
12 Seal, 1-5/16 " ID x 1-11/16 " OD 1 326750-B1 (22)
13 Spacer 1 335481 (24)
14 339606 Washer, 1.56 '' 1 335483 (23)
15 338106 Rod 1 338059 (13)
16 338120 Piston (Nylon) 1 338060 (11)
17 Ball, 9/16 " Dia. 1 338089 (8)
18 323707 Seat, Valve 1 338090 (21)
19 O-Ring, 1-7/8 " ID x 2 " OD 1 338091 (20)
20 Ring, Back-Up 1 338106 (15)
21 338090 Tube 1 338120 (16)
22 326750-B1 Adapter, Bung, 2 " NPTF (m) 1 Model 9968, -M 339375 (1d)
23 Washer, 1-1/8 " OD 1 339412 (9)
24 Spring, Tapered 1 339413 (1)
25 172270-13 Ball, 1-1/16 " Dia 1 339413-A (1)
26 O-Ring, 1-11/16 " ID x 1-7/8 " OD 1 339425 (1c)
27 323778 Valve, Foot 1 339429 (4)
28 323713 Pin, 1/4 " Dia. x 1-25/32 " Long 1 339606 (14)
29 340120 Adapter, 1/2 " BSPP (f) x 1/2 " NPTF (m) 1 Model 9968-M 340027 (1b)
Kit Component for Early Model 9668 Pump 340053 (1a)
x 323693 Gasket (Aluminum) 1 340120 (29)
Legend:
* See Table 1
Part numbers left blank (or in italics) are not available separately
designates a repair kit item

SER 9968 Low-Pressure Stub Pump
Revision (8-10) 4 Alemite, LLC
Accessories
Performance Curves
A pump’s ability to deliver fluid is based on the pressure (psi/bar) and quantity
(cfm/lpm) of air supplied to the motor and the amount of fluid 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 fluid discharge pressure in psi/bar (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
Cover Assembly Description Drum
5-Gallon 16-Gallon 55-Gallon
Bolt-On - 338145 * -
w/ 2-Inch Bung Adapter Fitting 327817-4 338977 * 318040-4
* w/ sealing gasket
Table 2 Low-Pressure Stub Pump Model 9968 Series Accessories
Figure 3 Delivery versus Discharge Pressure and Air Consumption

Low-Pressure Stub Pump SER 9968
Alemite, LLC 5 Revision (8-10)

SER 9968 Low-Pressure Stub Pump
Revision (8-10) 6 Alemite, LLC
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 fluid 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) or Body (8).
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 (9) from the Body.
6. Remove the Top Cap from the Cylinder.
CAUTION
Remove the Cylinder with care. Damage to Quad-
Ring (6) and/or O-Ring (7) can occur.
7. With a side-to-side motion, pull the Cylinder from the
Body and Air Piston (4).
8. Remove O-Ring (7) from the Body.
9. Remove the Bottom Cap from the Body.
Pump Tube Assembly
Tube Assembly
1. Unscrew Tube (21) from the Body.
Step for Model 9968 and 9968-M Only
2. Remove the Bung Adapter from the Tube as required.
3. Remove O-Ring (19) and Back-Up Ring (20) from the
Tube.
Air Piston Assembly
4. Remove Screw (2) that secures Air Piston (4) to
Rod (15).
• Remove the Air Piston from the Rod.
5. Remove Washer (3) Quad-Ring (6), and O-Ring (5)
from the Air Piston.
Rod Assembly
6. Pull the Rod assembly from the bottom of the Body.
7. Unscrew Valve Seat (18) from the Rod.
• Remove Ball (17) and Nylon Piston (16).
Body Assembly
8. Remove O-Ring (7) from the Body.
9. Remove Washer (14), Spacer (13) and Seal (12) from
the Body.
10. Remove Bearing (11) and Seal (10) from the Body.
Step for Model 9968-M Only
11. Unscrew Adapter (29) from the Body only when
necessary.
• Adapter is secured with Loctite 242.

Low-Pressure Stub Pump SER 9968
Alemite, LLC 7 Revision (8-10)
Assembly
NOTE: Prior to assembly, certain compo-
nents require lubrication. Refer to Table 3
for details.
NOTE: Refer to Figure 4 for a section view
of the pump tube assembly.
Foot Valve
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.
Body
4. Install O-Ring (7) onto the upper groove of Body (8).
5. Install and seat Seal (10) [heel end first] into the
bottom of the Body.
6. Install and seat Bearing (11) [small diameter first] into
the Body.
7. Install and seat Seal (12) [heel end first] into the Body.
8. Install Spacer (13) [small diameter first] and Washer
(14) into the Body.
Step for Model 9968-M Only
9. Screw Adapter (29) [with Loctite 242] into the Body
as required.
Tube and Rod
10. Install and seat Nylon Piston (16) [openings upward]
onto the bottom of Rod (15).
Foot Valve Assembly
12. Unscrew Foot Valve (27) from Tube (21).
13. Remove O-Ring (26) from the Foot Valve.
14. Remove Pin (28) from the Foot Valve.
15. 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 (4) 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.
Item No. Description Item No. Description
Clean Oil
5 O-Ring, 3/8 " ID x 1/2 " OD 10 Seal, 1-5/16 " ID x 1-9/16 " OD
6 Quad-Ring, 2-5/8 " ID x 3 " OD 12 Seal, 1-5/16 " ID x 1-11/16 " OD
7 O-Ring, 2-3/4 " ID x 3 " OD 19 O-Ring, 1-7/8 " ID x 2 " OD
26 O-Ring, 1-11/16 " ID x 1-7/8 " 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

SER 9968 Low-Pressure Stub Pump
Revision (8-10) 8 Alemite, LLC
11. 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. Dis-
tortion of the Nylon Piston can
occur which causes excessive drag
on the Tube.
12. Screw Valve 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 twist-
ing motion. Use care not to damage the
Seals.
13. Install the Rod assembly into the bottom of
the Body.
• Position the Nylon Piston flush with the
bottom of the Body.
14. Install Back-Up Ring (20) [concave upward]
onto Tube (21).
15. Install O-Ring (19) on top of the Back-Up
Ring.
16. Screw and seat the Tube assembly into the
Body.
• Make sure both Rings are not visible.
Step for Model 9968 and 9968-M Only
17. Slide Bung Adapter (22) onto the Tube.
18. Screw the Foot Valve assembly into the
Tube.
• Tighten the Foot Valve assembly securely
to the Tube and the Tube to the Body.
Air Piston
19. Install Quad-Ring (6) onto Air Piston (4).
20. Install and seat O-Ring (5) into the bottom of
the Air Piston.
21. Place the Air Piston [observe THIS SIDE
UP) on top of the Rod.
22. Install Screw (2) and Washer (3) that secures
the Air Piston to the Rod.
• Tighten the Screw to 15 ft.-lbs. (20.7 Nm).
Figure 4 Pump Tube Assembly 338067-B1- Section View
Refer to Figure 2 Parts List
for Parts Identification

Low-Pressure Stub Pump SER 9968
Alemite, LLC 9 Revision (8-10)
Attach Air Motor to Pump Tube
23. Clamp the pump assembly in a soft-jaw vise at Bung
Adapter (22) or Body (8).
24. Install the Bottom Cap onto the Body.
25. Install O-Ring (7) onto the upper groove of the Body.
CAUTION
Install the Cylinder with care. Damage to Quad-
Ring (6) and/or O-Ring (7) can occur.
HINT: Angle the Cylinder onto the Quad-
Ring.
26. Install the Cylinder over the Body’s O-Ring and seat it
properly onto the Bottom Cap.
27. Install the Top Cap onto the Cylinder.
• Use care passing the O-Ring.
28. Install Keeper (9) into the groove of the Body.
• Make sure the hole aligns with Carriage Bolt (1c).
29. Install one Carriage Bolt through the Air Motor and
through the Keeper.
30. Install Flange Nut (1d).
• Do not tighten the Flange Nut at this time.
31. Repeat procedural steps 27 - 29 for the additional
Keepers and Carriage Bolts.
CAUTION
Do not overtighten Flange Nuts (1d). Component
damage can occur.
32. Torque each Flange Nut in an alternate pattern from 60
to 70 inch-pounds (6.8 - 7.9 Nm).
33. Install Screw (1b) into the Top Cap.
• Tighten the Screw to 50 inch-pounds (5.6 Nm).
34. "Snap" Cover (1a) onto the Cylinder.
Bench Test and Operation
1. 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:
2. Connect a product hose to the pump’s fluid 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.
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

SER 9968 Low-Pressure Stub Pump
Revision (8-10) 10 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
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 (8)1. Damaged Seal (12) 2. Damaged Rod (15)1. Replace Seal (12) 2. Inspect Rod (15) and replace as necessary
Product leakage visible at
bottom of Body (8)1. Tube (21) not sufficiently tight 2. Damaged O-Ring (19)1. Tighten Tube (21) into Body (8) 2. Separate Tube (21) from Body (8) and
replace O-Ring (19)
Air leakage at weep hole in
Body (8)Damaged Seal (10) Replace Seal (10)
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
Continuous slow air leak Worn or damaged O-Ring (7) Replace O-Ring (7)
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
Added item 5 to Repair Kit. Items 8 and 13 no longer available