RAM 339610-1 User manual

Service Guide
SER 339610-1
339610-1
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
670854 and is not to be copied, used, or disclosed to others without express written permission. Revision (8-06)
Figure 1 Low-Pressure Transfer Pump Model 339610-1
Description
The major components of model 339610-1 transfer pump
consist of an air-operated motor (equipped with a shut-off
valve) 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
Maximum Air
Pressure
Inches Centimeters psi Bars
3 x 3-5/16 7.6 x 8.4 1/4 " NPTF (f) 150 10.3
For details on the air motor, refer to Service Guide SER 339413
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 339610-1 Specifications
Low-Pressure Transfer Pump
Overall Height Weight
Inches Cm lbs kg
18 45.7 14.7 6.7
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SER 339610-1 Low-Pressure Transfer Pump
Revision (8-06) 2
Figure 2 Low-Pressure Transfer Pump Model 339610-1 - Exploded View
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Low-Pressure Transfer Pump SER 339610-1
3 Revision (8-06)
Repair Kits
Part No. Kit Symbol Description
393763 Kit, Major Repair (Includes tube of 393590 Teflon Grease)
393708 Kit, Repair, Air Motor Keeper
393530-24 Kit, Seal [includes five (5) of item number 14]
393530-26 Kit, Seal [includes five (5) of item number 16]
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
1 Motor Assembly, Air 1 See SER 339413 14536 (4)
1a 340053 Cover (w/o Decals) 1
Included w/
Motor Assembly
51929 (24)
1b Screw, Cap, 1/4 " -20 x 6-1/2 " 1 170710 (20)
1c Bolt, Carriage, 1/4 " -20 x 7-1/2 " 4 X171000-7 (7)
1d Nut, Serrated Flange, 1/4 " -20 4 X171000-105 (12)
2 319391 Valve, Shut-Off 1 X171003-10 (9)
3 339513 Nut, Flange, 3/8 " -24 1 171006-17 (18)
4 Washer, 3/8 " ID x 7/8 " OD 1 X171008-37 (6)
5 339429 Piston, Air 1 172190-24 (14)
6 X171008-37 Quad-Ring, 2-5/8 " ID x 3 " OD 1 Pack of Ten (10) 172190-26 (16)
7 X171000-7 O-Ring, 3/8 " ID x 1/2 " OD 1 319391 (2)
8 338109 Washer, 3/8 " ID x 3/4 " OD 1 320531 (13)
9 X171003-10 O-Ring, 2-3/4 " ID x 3 " OD 1 Pack of Ten (10) 323474 (17)
10 339971 Body, Pump 1 338109 (8)
11 339412 Keeper 4 338259 (23)
12 X171000-105 O-Ring, 3 " ID x 3-1/8 " OD 2 Pack of Ten (10) 338271 (21)
13 320531 Bushing, 3/4 " NPTF (m) x 1/2 " NPTF (f) 1 338272 (22)
14 Seal, 1/2 " ID x 3/4 " OD 1 338339-2 (27)
15 339976 Bearing (Brass) 1 339375 (1d)
16 Seal, 1/2 " ID x 7/8 " OD 1 339412 (11)
17 Washer 1 339413 (1)
18 Ring, Retaining, Internal 1 339425 (1c)
19 339974 Rod 1 339429 (5)
20 Ring, Retaining, External 1 339513 (3)
21 338271 Piston, Fluid (Nylon) 1 339971 (10)
22 Gasket (Aluminum) 1 339972 (25)
23 338259 Plate (Stainless Steel) 1 339973 (28)
24 Nut, Elastic Stop, 3/8 " -24 1 339974 (19)
25 339972 Cylinder 1 339976 (15)
26 340189 Stop 1 340027 (1b)
27 338339-2 Ball, Check 1 340053 (1a)
28 339973 Body, Valve 1 340189 (26)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
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SER 339610-1 Low-Pressure Transfer Pump
Revision (8-06) 4
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 339610-1339610-1 Accessory Components
Figure 3 Delivery versus Discharge Pressure and Air Consumption
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Low-Pressure Transfer Pump SER 3396101-1
5 Revision (8-06)
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 at
Valve Body (28).
2. Remove Cover (1a).
• Pry and swing the Cover sideways away from the
Cylinder.
• Refer to SER 339413 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 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 (6) and/or O-Ring (9) can occur.
7. With a side-to-side motion, pull the Cylinder from the
Body and Air Piston (5).
8. Remove O-Ring (9) from the Body.
9. Remove the Bottom Cap from the Body.
10. Unscrew Shut-Off Valve (2) from the Air Motor
Assembly as required.
Pump Assembly
11. Unscrew the Pump Body from Cylinder (25).
NOTE: Use Bushing (13) as leverage.
12. Remove O-Ring (12) from the Pump Body.
Air Piston Assembly
13. Remove Nut (3) and Washer (4) that secures Air
Piston (5) to Rod (19).
NOTE: Place an appropriate size punch or
other suitable tool into the hole of the Rod.
14. Remove the Air Piston from the Rod.
15. Remove Quad-Ring (6) from the Air Piston.
16. Remove O-Ring (7) and Washer (8) from the Rod.
Rod and Fluid Piston Assembly
17. Remove the Rod (with attached components) from the
Pump Body.
18. Remove lower Nut (24) that secures Fluid Piston (21) to
the Rod.
NOTE: Place an appropriate size punch or
other suitable tool into the hole of the Rod.
19. Remove Plate (23), Gasket (22), and the Fluid Piston
from the Rod.
20. Remove Retaining Ring (20) from the Rod as needed.
Pump Body Assembly
21. Remove O-Ring (9) from the Pump Body.
22. Remove Retaining Ring (18), Washer (17), Seal (16),
Bearing (15), and Seal (14) from the Pump Body.
23. Unscrew Bushing (13) from the Pump Body as required.
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SER 339610-1 Low-Pressure Transfer Pump
Revision (8-06) 6
Pump Body Assembly
1. Install and seat Seal (14) [stem end first], Bearing (15)
[stepped end first], Seal (16) [stem end first], and
Washer (17) into the bottom of Pump Body (10).
2. Secure the components with Retaining Ring (18).
• Make sure the Retaining Ring seats properly in the
groove.
3. Install O-Ring (9) onto the top groove of the Pump
Body.
• Install O-Ring (12) onto the bottom groove of the
Pump Body.
4. Screw Bushing (13) [with thread sealant] into the
Pump Body as required
• Tighten the Bushing securely.
Rod and Fluid Piston
5. Install Retaining Ring (20) onto Rod (19) as required.
IMPORTANT: Make sure the ground side of
Plate (23) contacts Fluid Piston (21).
6. Install Fluid Piston (21) [segmented side first], Gasket
(22), and Plate (23) [ground side first] onto the bottom
of the Rod.
7. Install Nut (24) 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.
8. Install the Rod assembly into the bottom of the Pump
Body.
• Position the Fluid Piston flush with the bottom of the
Body.
Valve Body Assembly
24. Unscrew Valve Body (28) from Cylinder (25).
25. Remove O-Ring (12) , Stop (26), and Ball (27) from
the Valve Body.
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 (5) and Fluid Piston (21) for fatigue
cracks.
• Replace as necessary.
4. Inspect Rod (19) 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 (27) into Valve
Body (28). Fill the Valve Body 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.
Item No. Description Item No. Description
Clean Oil
7O-Ring, 3/8 " ID x 1/2 " OD 12 O-Ring, 3 " ID x 3-1/8 " OD
9O-Ring, 2-3/4 " ID x 3 " OD 16 Seal, 1/2 " ID x 7/8 " OD
Magnalube-G Teflon Grease
8 Quad-Ring, 2-5/8 " ID x 3 " OD 14 Seal, 1/2 " ID x 3/4 " OD
Coat the Inside Diameter of the Air Motor Assembly
Table 3 Lubricated Components
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Low-Pressure Transfer Pump SER 3396101-1
7 Revision (8-06)
Air Piston
CAUTION
Use care not to switch Washers (4 and 8). Com-
ponent damage can occur.
9. Install Washer (8) [brass color] , O-Ring (7), and
Air Piston (5) (observe THIS SIDE UP] onto the
Rod.
10. Install Washer (4) [silver color] and Nut (3) 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.
11. Install Quad-Ring (6) onto the Air Piston.
Cylinder
12. Screw Cylinder (25) onto the Pump Body.
• Use care passing the O-Ring.
• Do not tighten at this time.
Stop and Valve Body Assembly
13. Install O-Ring (12) onto Valve Body (28).
14. Install Ball (27) and Stop (26) into the Valve Body.
• Make sure the Stop seats fully into the groove.
15. Screw the Valve Body assembly into the Cylinder.
• Use care passing the O-Ring.
16. Clamp the Valve Body securely in a soft-jaw vise.
17. Tighten the Pump Body securely into the Cylinder
and at the same time the Cylinder onto the Valve
Body.
• Use Bushing (13) as leverage.
Attach Air Motor to Pump Tube
18.Clamp the pump assembly in a soft-jaw vise at
Valve Body (28).
19. Install the Bottom Cap onto the Body.
20. Install O-Ring (9) onto the upper groove of the
Body.
CAUTION
Install the Cylinder with care. Damage to Quad-
Ring (6) and/or O-Ring (9) can occur.
HINT: Angle the Cylinder onto the
Quad-Ring.
Figure 4 Pump Tube Assembly (w/o Air Motor) - Section View
Refer to Figure 2 Parts List for Parts Identification
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SER 339610-1 Low-Pressure Transfer Pump
Revision (8-06) 8
21. Install the Cylinder over the Body’s O-Ring and seat it
properly onto the Bottom Cap.
22. Install the Top Cap onto the Cylinder.
• Use care passing the O-Ring.
23. Install Keeper (11) into the groove of the Body.
• Make sure the hole aligns with Carriage Bolt (1c).
24. Install one Carriage Bolt through the Air Motor and
through the Keeper.
25. Install Flange Nut (1d).
• Do not tighten the Flange Nut at this time.
26. Repeat procedural steps 23 - 25 for the additional
Keepers and Carriage Bolts.
CAUTION
Do not overtighten Flange Nuts (1d). Component
damage can occur.
27. Torque each Flange Nut in an alternate pattern from 60
to 70 inch-pounds (6.8 - 7.9 Nm).
28. Install Screw (1b) into the Top Cap.
• Tighten the Screw to 50 inch-pounds (5.6 Nm).
29. "Snap" Cover (1a) onto the Cylinder.
30. Screw Shut-Off Valve (2) [with thread sealant] into the
Air Motor Assembly.
• Tighten the Shut-Off Valve securely in the position
required.
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 [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 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.
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Low-Pressure Transfer Pump SER 3396101-1
9 Revision (8-06)
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 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 Pump Body (10)
1. Damaged Seal (16)
2. Damaged Rod (19)
1. Replace Seal (16)
2. Inspect Rod (19) and replace as necessary
Product leakage visible at top
of Cylinder (25)
1. Cylinder (25) not sufficiently tight
2. Damaged O-Ring (12)
1. Tighten Cylinder (25) into Pump Body
(10)
2. Replace O-Ring (11)
Product leakage visible at
bottom of Cylinder (25)
1. Cylinder (25) not sufficiently tight
2. Damaged O-Ring (12)
1. Tighten Cylinder (25) into Valve Body
(28)
2. Replace O-Ring (12)
Air leakage at weep hole in
Pump Body (10)
Damaged Seal (14) Replace Seal (14)
Internal Leaks
Pump does not prime or
cycles continuously, or
slowly (once or twice/hour)
1. Foreign material between Ball (27)
and Valve Body (28)
2. Foreign material between Plate (23)
and Fluid Piston (21)
3. Worn or damaged Ball (27)
4. Worn or damaged Valve Body (28)
5. Worn or damaged Plate (23)
6. Worn or damaged Fluid Piston (21)
7. Worn or damaged Cylinder (25)
Locate and eliminate source of foreign
material.
Disassemble pump tube, clean, inspect, and
replace worn or damaged components
Changes Since Last Printing
Replaced Stop 339975 with 340189
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 339610-1 Low-Pressure Transfer Pump
Revision (8-06) 10
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