Alemite 8540-B Bedienungsanleitung

SERVICE GUIDE 8540-B

8549-B1

8549-C

DESCRIPTION

The major components of the high-pressure pump models in this

series consist of a(n):

• air-operated motor

• lubricant pressure controller (pressurtrol)

• double-acting reciprocating pump tube.

The pressurtrol minimizes material pressure drop that occurs when

the pump cycles. Refer to SER 319800-1.

Pump Assembly

These high-pressure (70:1 ratio) pumps are designed to deliver a

range of greases [up to NLGT # 3] and operate directly from their

original container.

Models 8540-B, 8549-B1, and 8549-C

Pump model 8540-B is designed with a pump tube length to ac-

commodate 120-pound (50 kg) containers.

The 8549 series pumps are for 400-pound (180 kg) containers with

model 8549-B1 including a bung adapter. See Figure 1.

Specifications

Air Motor

Figure 1 Pump Models 8540-B and 8549 Series

Model 8549-B1 Shown

Alemite , LLC

167 Roweland Drive, Johnson City, Tennessee 37601

www .alemite.com

670763

SER 8540-B

Revision (12-14)

High-Pressure Lubricant Pump

Piston Diameter x Stroke Air Inlet

Max. Air Pressure *

Inches Centimeters psi Bars

3 x 1-5/8 76.2 x 41.3 1/4″NPTF (f) 200 13.8

* With pressurtrol, [100 psi (6.9 Bars) without pressurtrol] For information

on the air motor, refer to SER 324400-5

Pump tube

Material Outlet Max. Material Pressure Max. Delivery/ Minute

(Approximate)*

Displacement per

Cycle

psi Bars Ounces Grams in 3cm3

3/8″NPTF (f) 7500 517 32 909 0.277 4.54

* For detailed information, refer to Figure 4

Pump

Model

Container Size Bung

Adapter

X (X1) y

lbs kgs Inches Cm Inches Cm

8540-B 120 50 27-3/4 70.5 38-1/8 96.8

8549-B1 ●37 (35) 94 (89)

47-3/8 120.3

8549-C 400 180 37 94

SER 8540-B High Pressure Lubricant Pump

Figure 2 High-Pressure Lubricant Pump Models 8540-B and 8549 Series- Exploded View

SER 8540-BHigh Pressure Lubricant Pump

Repair Kits

Item

No.

Part No. Description Qty Notes

Numeric Order

Part # Item #

1 170292 Screw, Machine 8-32 x 1-1/4″ Long 1 43748 6

2 321085 Mufer 1 51017 14

3Motor Assembly, Air 1 See SER 324400-5 131168 38

4 327033 Adapter, 1/4″ NPTF (m) 1 170292 1

5 319800-1 Pressurtrol 1 See SER 319800-1 171000-20 42

6 43748 Body, Angle, 1/4″NPTF (m) and (f) 1 171013-12 12

7 328034 Connector, Air, 1/4″NPTF (m) 1 171033-5 17

8 328030 Coupler, Air, 1/4″NPTF (f) 1 171700-12 23

9 338507 Fitting, 90 °, 3/16″Tube x 1/8″NPTF (m) 2 l72l90-9 29

10 324971 Adapter, 3/8″PTF (f) x 3/8″NPTF (m) 1 l72l90-l0 34

11 324443 Tube, 3/16″OD 1 317536 24

12 171013-12 O-Ring, 1-1/8″TD x 1-1/4″ OD 1 ●Δ 317549 33

13 324805 Adapter 1 319800-1 5

14 51017 Gasket (Aluminum) 4 ●Δ 320704-1 18

15 320974 Coupling 1 320704-3 18

16 320971 Pin, 0.088″Dia. x 41/64″ Long 1 ●Δ 320705 19

17 171033-5 Pin, 1/8″ Dia. x .625″ Long 2 ●Δ 320712 40

18 320704-1 Rod, 17.75″ Long 1 Model 8540-B 320713 39

320704-3 Rod, 27.06″ Long 1 Model 8549-B1, -C 320716 36

19 320705 Coupling 1 320718 20

20 320718 Stop, Ball 1 320719 22

21 321605 Washer 1 328030 8

22 320719 Spring, 0.75″ Long 1 ●Δ 328034 7

23 171700-12 Ball, 3/16″ Dia. 1 ●Δ 320971 16

24 317536 Washer, Locking 1 ●Δ 320974 15

25 330332 Piston 1 Δ321085 2

337392 Tube, 21.25″ Long 1 Model 8540-B 321605 21

26 337392-2 Tube, 30.42″ Long 1 Model 8549-B1, -C 324400-5 3

27 Bearing (Brass) 1 ●Δ 324437 43

28 337391 Retainer 1 Δ324438-1 41

29 Seal, 0.540″ ID x 0.914″ OD 1 ●Δ 324438-2 41

30 Bearing (Brass) 1 ●Δ 324443 11

31 Gasket (Aluminum) 1.08″ ID 1 ●Δ 324805 13

32 337388 Extension 1 Δ324971 10

33 317549 Washer, Stop 1 ●Δ 326750 44

34 Seal, 0.282″ ID x 0.532″ OD 1 ●Δ 327033 4

35 337995 Body, Valve 1●Δ 330329 37

36 320716 Seat, Valve 1●Δ 330332 25

37 330329 Rod, 3.91″ Long 1 Δ330334 31

38 131168 Pin, 1/16″ Dia. x 0.50″Long 1 ●Δ 337388 32

39 320713 Disc, Primer 1 ●Δ 337389 30

40 320712 Nut, Elastic Stop, 12- 28 1 ●Δ 337391 28

41 324438-1 Tube, Follower, 25-9/16″Long 1 Model 8540-B 337392 26

324438-2 Tube, Follower, 34-11/16″ Long 1 Model 8549-B1, -C 337392-2 26

42 171000-20 O-Ring, 1-1/16″ TD x 1-5/16″OD 1 ●Δ 337393 27

43 324437 Body, Primer 1 337995 35

44 326750 Adapter, Bung, 2″ NPTF (m) 1 Model 8549-B1 338507 9

Legend:

Part numbers left blank (or in italics) are not available separately

●Δ designates a repair kit item

Part No. Kit

Symbol Description Notes

393514 ● Kit, Major Repair

393516 ΔKit, Conversion See Page 4

393530-9 Kit, Seal [includes ve (5) of item number 29]

393530-10 Kit, Seal [includes ve (5) of item number 34]

SER 8540-B High Pressure Lubricant Pump

Early Model Pumps

The earlier versions of these model pumps did not contain seals in

the tube assembly. The Piston and Lower Rod cycled in “select-fit”

bores. See Figure 3.

Any earlier model pump that has not been repaired since 1983 re-

quires a 393516 conversion kit.

Conversion Kit

NOTE: In addition to the contents within the kit, the existing pump

tube must be replaced. See Table 2 for the appropriate part number.

Install the Kit

To reassemble the pump with the conversion kit, follow the proce-

dures outlined in the section entitled Assembly.

1 Pump Model Pump Tube

Part No. Length

8540-B 337392 21.25″

8549 Series 337392-2 30.42″

Noise level test

Distance 60 psi (4,1 bar) 100 psi (6,8bar)

3 ft. (0,9 m)96 dB 98 dB

Figure 3 Early Model Pump Tubes- Section View

SER 8540-BHigh Pressure Lubricant Pump

Accessories

2 Model

Number

Container

Size Follower Cover Bung Adapter

8540-B 120 lbs 338802 338371 326750

50 kg 338993 338983

8549-B1 400 lbs 338911 318040-4 Included with

Model

180 kg 338994 338984

8549-C

400 lbs 338911 318040-4

326750

180 kg 338994 338984

Performance Chart

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 ounces (grams) per minute (X axis) to air con-

sumption in cubic feet (liters) per minute (right Y axis) and to material discharge pressure in psi/Bars (left Y axis).

Table 3 Pump Models 8540-B and 8549 Series Accessories

Figure 4 Delivery Versus Discharge Presure And Air Consumption

SER 8540-B High Pressure Lubricant Pump

SER 8540-BHigh Pressure Lubricant Pump

IMPORTANT:Prior to performing any maintenance procedure, the

following safety precautions must be observed. Personal in}ury

may occur.

WARNING

Do not use halogenated hydrocarbon solvents such

as methylene chloride or 1,1,1-trichloroethane in this pump. An

explosion can result within an enclosed device capable of con-

taining 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 anoth-

er person. Accidental discharge of pressure and/or material can

result in injury.

Read each step of the instructions carefully. Make sure a prop-

er understanding is achieved before proceeding.

Overhaul

NOTE: Refer to Figure 2 for component identification on all

overhaul procedures.

Disassembly

1 Secure the pump assembly in a soft-jaw vise at Adapter (13).

NOTE: Secure model 8549-B1 at Bung Adapter (44).

2 Extend Rod (37) to end of Primer Body (43).

• Apply air to the motor as necessary.

3 Gently remove Nut (40) from the Rod.

• Use an appropriate size punch in the hole of the Rod to prevent

rotation. See Figure 2.

4 Remove Primer Disc (39) from the Rod.

5 Push the Rod into the Primer Body.

Pump Tube (Outer Components)

6 Rotate the Primer Body.

• Use a large wrench or other suitable tool.

NOTE: The pump tube will break at one of three places. Unscrew

the separated portion from the inner components of the pump tube

assembly.

7 Remove Follower Tube (41) [assembly] from the inner tube

assembly.

8 Unscrew the air motor from Adapter (13).

• Rotate the air motor assembly.

9 Remove O-Ring (12) from the Adapter.

NOTE: If the pump was not leaking at the top of Tube (26), do not

separate the Adapter from the Tube. Components are locked with

Loctite® 222 ™.

10 Unscrew Tube (26) from the Adapter as required.

• Remove Gasket (14).

11 Clamp Retainer (28) horizontally in a soft-jaw vise.

12 Unscrew the Primer Body from Extension (32).

13 Remove O-Ring (42) from the Primer Body.

IMPORTANT: Remove Valve Seat (36) squarely from the Primer

Body. Should the Valve Seat cock during removal, realign and

start again. Gasket (14) may interfere.

14 Remove Valve Seat (36) from the Primer Body.

15 Remove Gasket (14) from the Valve Seat.

16 Unscrew the Extension from the Retainer.

17 Remove Gasket (31) from the Extension.

18 Remove Valve Body (35) from the Extension.

•Remove Stop Washer (33).

19 Remove Seal (34) from the Valve Body.

20 Remove Bearing (30) and Seal (29) from the Retainer.

21 Unscrew Tube (26) from the Retainer.

22 Remove Gasket (14), Bearing (27), and additional Gasket (14)

from the Retainer.

SER 8540-B High Pressure Lubricant Pump

Pump Tube (Inner Components)

23 Remove Pin (16) that secures Coupling (15) to the air motor rod.

•Unscrew the Coupling assembly from the air motor rod.

24 Clamp Coupling (19) in a soft-jaw vise.

25 Remove upper Pin (17) that secures Coupling (15) to Rod (18).

• Unscrew the Rod from the Coupling.

26 Remove lower Pin (17) that secures Coupling (19) to the Rod.

• Unscrew the Rod from the Coupling.

27 Remove Pin (38) that secures Piston (25) to Rod (37).

• Unscrew the Rod from the Piston.

28 Straighten the tabs on Locking Washer (24).

29 Unscrew Piston (25) from the Coupling.

30 Remove the Locking Washer from the Piston.

31 Remove Ball (23) from the Piston.

32 Remove Spring (22) and Washer (21) from Ball Stop (20).

NOTE: Separate the Ball Stop from the Coupling only if the

connection is loose.

33 Unscrew the Ball Stop from the Coupling as needed.

Pressurtrol

34 Remove Air Coupler (8) from Air Connector (7).

35 Loosen both Fittings (9) that secure Tube (11).

36 Loosen Pressurtrol (5) from Adapter (4).

• Remove the Tube from the Fittings.

37 Unscrew the Pressurtrol from the Adapter.

• Remove the Adapter from Air Motor (3) as needed.

38 Unscrew the Fitting from the Pressurtrol as needed.

39 Unscrew Angle Body (6) from the Pressurtrol as needed.

40 Unscrew Air Connector (7) from the Angle Body as needed.

41 Unscrew the additional Fitting from Adapter (10) as needed.

42 Remove the Adapter from the Air Motor as needed.

Clean and Inspect

NOTE: Use the appropriate repair kit for replacement parts.

Make sure all the components are included in the kit and in good

condition before discarding 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 Piston (25) closely. Use a magnifying glass to detect any

wire draw marks.

• Replace as necessary.

4 Closely inspect the mating surfaces of all components for any im-

perfections. Ensure a smooth and clean contact is obtained when

assembled.

EXAMPLE: Place Ball (23) into Piston (25). Fill the Piston with

solvent. Make sure no leakage occurs.

Assembly

NOTE: Prior to assembly, certain components require lubrication

in clean oil. Refer to Table 4 for details.

Pump Tube (Inner Components)

NOTE: Refer to Figure 5 for a section view of the pum p tube

assembly.

1 Place Ball (23) into Piston (25).

2 Screw and seat Ball Stop (20) [ Loctite®242®]. into Coupling (19).

• Follow the thread sealant manufacturer’s recommendations.

• Tighten securely.

3 Install Washer (21) and Spring (22) onto the Ball Stop.

Item No. on

Figure 2 Description

12 O-Ring, 1-1/8″TD x 1-1/4″OD

29 Seal, 0.540″TD x 0.914″OD

34 Seal, 0.282″TD x 0.532″OD

42 O-Ring, 1″ TD x 1-1/4″OD

4 Position Locking Washer (24) into the groove on the top of the

Piston.

5 Screw the Coupling assembly into the Piston.

• Tighten from 19 to 21 foot pounds (25.4 - 28.3 Nm)

• Continue to tighten and align the nearest flat of the Coupling

with the tabs on the Locking Washer.

IMPORTANT: Press on the Ball to ensure it moves a minimum of

1/8″(3.2 mm) prior to contact with the Ball Stop. Should the value

be less, check to ensure the Ball Stop is fully seated in the Coupling.

6 Bend the tabs of the Locking Washer upward onto the Coupling.

7 Screw Rod (37) into the Piston until the pin holes align.

NOTE: Use a spot of grease on all pins to prevent

movement.

8 Install Pin (38).

SER 8540-BHigh Pressure Lubricant Pump

Figure Pump Tubes 337384-Al, and Bl - Section View

9 Screw Rod (18) into Coupling (19) until

the pin holes align.

• Install Pin (17).

10 Screw Coupling (15) [end without coun-

ter-bore] onto the Rod until the pin holes

align.

• Install additional Pin (17).

11 Secure the air motor assembly in a soft-jaw

vise.

12 Screw the Coupling assembly onto the

air motor rod until the pin holes align.

• Install Pin (16).

Pump Tube (Outer Components)

13 Install and seat Seal (29) [lips first] into the

bottom of Retainer (28). See Figure 2.

14 Install and seat Bearing (30) into the bot-

tom of the Retainer.

15 Install Gasket (31) onto the top of Exten-

sion (32).

IMPORTANT: If a primer is used with

Loctite 222 , the curing time is greatly

reduced.

16 Screw the Extension [with Loctite 222]

(Gasket end first) into the bottom of the

Retainer.

• Follow the thread sealant manufactur-

er’s recommendations.

• Do not tighten at this.

17 Install Gasket ( 14 ) into the top of the

retainer.

18 Install and seat Bearing (27) [small diam-

eter first] and additional Gasket (14) into

the top of the Retainer.

19 Screw Tube (26) [with Loctite 222] into

the top of the Retainer.

• Do not tighten at this time.

20 Install and seat Gasket (14) into Adapter

(13).

21 Screw the Tube assembly [with Loctite

222] into the Adapter.

• Do not tighten at this time.

22 Install O-Ring (12) onto the Adapter.

23 Apply grease to Piston ( 25 )

• This will aid the installation

SER 8540-B High Pressure Lubricant Pump

CAUTION

Install the outer component assembly onto the inner assembly

with care. Damage to Seal (29) can occur.

24 Install the outer component assembly onto the inner assembly.

• Use a slight twisting motion to pass the Seal

•At the same time thread the Adapter into the base of the air

motor.

IMPORTANT: Make sure the flange portion of the Adapter seats

flush against the base of the air motor. Should a gap exist, inspect

the components of the air motor packing group.

25 Install Stop Washer (33) into the Extension.

26 Install and seat Seal (34) [heel end first] into Valve Body (35).

27 Install the Valve Body assembly (Seal first) onto Rod (37).

•Make sure the Valve Body assembly seats properly in the

Extension.

28 Install Follower Tube (41) over the outer tube assembly.

29 Install O-Ring (42) onto Primer Body (43).

30 Install and seat Valve Seat (36) [large diameter first] into the

Primer Body.

31 Install and seat Gasket (14) into the Primer Body.

32 Screw the Primer Body onto the Extension.

33 Place a large wrench or other suitable tool into the slot of the

Primer Body.

• Tighten all the components of the assembly securely.

• Crush all Gaskets.

34 Extend Rod (37) from the Primer Body.

• Apply air to the motor as necessary.

35 Install Primer Disc (39) onto the Rod.

36 Gently screw Nut (40) onto the Rod.

•Use an appropriate size punch in the hole of the Rod to prevent

rotation. See Figure 2.

• Do not overtighten.

Model Dependent Step

37 Install Bung Adapter (44) onto the Follower Tube.

model8549-Bl].

Pressurtrol

Screw Fitting (9) [with thread sealant] and Angle Body (6) [with

thread sealant] into the Pressurtrol.

• Tighten each component securely.

• Make sure to orient the components properly.

38 Screw Air Connector (7) [with thread sealant] into the Angle

Body.

• Tighten the Air Connector securely.

39 Screw Adapter (4) [with thread sealant] into Air Motor (3).

•Tighten the Adapter securely.

40 Screw Pressurtrol (5) onto the Adapter [with thread sealant].

IMPORTANT: Tighten the Pressurtrol just short of vertical. This

allows the assembly of Tube (11).

41 Screw Adapter (10) into the Air Motor.

• Tighten the Adapter securely.

• Make sure to orient the Adapter properly.

42 Screw additional Fitting (9) into the Adapter.

• Tighten the Fitting securely.

• Make sure to orient the Fitting properly.

43 Position Tube (11) into each Fitting.

44 Secure the Tube by rotating the Pressurtrol to vertical.

• Tighten the Fittings to the Tube.

45 Install Air Coupler (8) onto the Air Connector.

Operation

WARNING

Do not exceed the lowest pressure rating of any

component in the system.

Do not alter the design of the pump. Never install addition-

al components to the outlet of the pressurtrol.

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 flu-

id 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 pressurtrol’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 system and grease is free

of air.

If the pump assembly does not prime, refer to the Troubleshooting

Chart for details.

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