Alemite 9616-A Bedienungsanleitung

Service Guide

SER 9616-A

9616-A

Alemite Corporation

PO Box 473515, Charlotte, North Carolina 28247-3515

www.alemite.com

1998 by Alemite Corporation

This document contains conﬁdential information that is the property of Alemite Corporation

670546

and is not to be copied, used, or disclosed to others without express written permission.

Revision (10-98)

2 " NPTF (m)

[1-1/2 " NPTF (f)]

Air Inlet Material

Outlet

Material

Inlet

Shut-Off Valve

Figure 1

Low-Pressure Transfer Pump Model 9616-A

Description

The major components of model 9616-A transfer

pump consist of an air-operated motor 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

Max. Air

Pressure

Inches Millimeters psi Bars

2-15/16 x 3 74.6 x 76.2 1/4 " NPTF (f) 150 10.3

For information on the air motor, refer to

SER

338066-A1

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 9616-A Speciﬁcations

Low-Pressure Transfer Pump

Overall Height Weight

Inches Meter lbs kg

15-7/8 0.4 13 5.9

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SER 9616-A

Low-Pressure Transfer Pump

Revision (10-98) 2 Alemite Corporation

Point Ground

Side Upward

Place Punch Here

Apply Thread

Sealant Here

Apply Thread

Sealant Here

Weep

Hole

Figure 2

Low-Pressure Transfer Pump Model 9616-A - Exploded View

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Low-Pressure Transfer Pump

SER 9616-A

Alemite Corporation 3 Revision (10-98)

Repair Kits

Part No. Kit Symbol Description

393627

Kit, Major Repair (Includes tube of 393590 Teﬂon Grease)

393530-24 Kit, Seal [includes ﬁve (5) of item number

]

393530-26 Kit, Seal [includes ﬁve (5) of item number

]

Item

No. Part No. Description Qty Notes Numeric Order

Part # (Item #)

1 328030 Coupler, Air, 1/4 " NPTF (f) 1 51929 (5)

2 330605 Adapter, 1/4 " NPTF (f) 1 171000-7 (8)

3 319391 Valve, Shut-Off 1

171000-103

(7, a)

4 Motor Assembly, Air 1 See

SER

338066-A1

171003-10 (10)

5 51929 Nut, Elastic Stop 2

171006-17

(17)

6 338111 Piston, Air 1

171009-14

(30)

7 O-Ring, 2-5/8 " ID x 3 " OD 1

171009-27

(25)

8 171000-7 O-Ring, 3/8 " ID x 1/2 " OD 1 171009-35 (33)

9 338109 Washer, 3/8 " 1

171016-50

(19)

10 171003-10 O-Ring, 2-3/4 " ID x 3 " OD 2 171700-56 (29)

11 Body, Outlet 1

172190-24

(13)

12 320531 Bushing, 3/4 " NPTF (m) x 1/2 " NPTF (f) 1

172190-26

(15)

13 Seal, 1/2 " ID x 3/4 " OD 1 319391 (3)

14 338072 Ring, Lantern (Brass) 1 320531 (12)

15 Seal, 1/2 " ID x 7/8 " OD 1 323474 (16)

16 323474 Washer 1 328030 (1)

17 Ring, Retaining, Internal 1 330605 (2)

18 338589 Rod 1

338066-A1

(4)

19 Ring, Retaining, External 1 338072 (14)

20 338271 Piston, Fluid (Nylon) 1 338109 (9)

21 Gasket (Aluminum) 1 338111 (6)

22 338259 Plate (Stainless Steel) 1 338259 (22)

23 338591 Stop 1 338261 (26)

24 338590 Pin, 1/4 " Dia. x 1-5/8 " Long 1 338271 (20)

25 O-Ring, 1-7/16 " ID x 1-5/8 " OD 1

338272

(21)

26 338261 Cylinder 1 338283 (27)

27 338283 Ring 1

338588

(11)

28 338594 Screw, 5/16 " -18 x 2-1/2 " 4 338589 (18)

29 171700-56 Ball 1 338590 (24)

30 O-Ring, 1-1/4 " ID x 1-3/8 " OD 1 338591 (23)

31 338592 Seat 1 338592 (31)

32 338595 Spring, Disc 4 338593 (34)

33 171009-35 O-Ring, 1-15/16 " ID x 2-1/8 " OD 1 338594 (28)

34 338593 Body, Valve 1 338595 (32)

Kit Component for Model 9616-S

a O-Ring, 2-5/8 " ID x 3 " OD 1

Legend

Part numbers left blank (or in

italics

) are not available separately

designates a repair kit item

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SER 9616-A

Low-Pressure Transfer Pump

Revision (10-98) 4 Alemite Corporation

Legend:

Air Pressure

Material Discharge Pressure

Air Consumption

Material Discharge Pressure (psi)

Air Consumption (cfm)

SAE 10 Oil at 77 ° F

2 4 6 8 10 12 14

100

120

140

160

Gallons per Minute

Liters per Minute

lpm

cfm

psi

Bars

100

200

300

400

500

600

700

800

10 20 30 40 50 60

100 psi (6.9 Bars)

150 psi (10.3 Bars)

50 psi (3.4 Bars)

150 psi (10.3 Bars)

100 psi (6.9 Bars)

Delivery

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 9616-A Accessory Components

Figure 3

Delivery versus Discharge Pressure and Air Consumption

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Low-Pressure Transfer Pump

SER 9616-A

Alemite Corporation 5 Revision (10-98)

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.

2. Remove Capscrews (

) that secure Ring (

Cylinder (

), and Air Motor Assembly (

) to Outlet

Body (

• Remove the Ring from the Cylinder.

3. With a side-to-side motion, pull the Air Motor

Assembly from the Outlet Body.

• Lubricate upper O-Ring (

) with oil to ease

separation.

NOTE

: The following three (3) steps are

performed only as required.

4. Remove Coupler (

) from Adapter (

5. Unscrew the Adapter from Shut-Off Valve (

6. Unscrew the Shut-Off Valve from the Air Motor

Assembly.

Pump Tube Assembly

7. With a side-to-side motion, pull the Cylinder assembly

from the Outlet Body.

• Lubricate lower O-Ring (

) with oil to ease

separation.

8. Unscrew Bushing (

) from the Outlet Body as

required.

9. Remove O-Rings (

) from the Outlet Body.

10. Remove O-Ring (

) from Air Piston (

11. Unscrew Valve Body (

) from Stop (

• Use a 2-inch socket to secure the Stop.

12. Remove O-Ring (

) from the Valve Body.

13. Remove O-Ring (

) from the Stop.

14. Remove Pin (

) from the Stop as required.

15. Remove Ball (

), Seat (

), and Spring Discs (

)

from the Valve Body.

16. Remove O-Ring (

) from the Seat.

17. Remove upper Nut (

) that secures Air Piston (

) to

Rod (

• Remove the Air Piston from the Rod.

NOTE

: Place an appropriate size punch or

other suitable tool into the hole of the Rod.

See

Figure 2

18. Remove O-Ring (

) and Washer (

) from the Upper

Rod.

19. Remove the Rod (with attached components) from the

Outlet Body.

20. Remove lower Nut (

) that secures Fluid Piston (

) to

the Rod.

NOTE

: Place an appropriate size punch or

other suitable tool into the hole of the Rod.

21. Remove Plate (

), Gasket (

), and the Fluid Piston

from the Rod.

22. Remove Retaining Ring (

) from the Rod as needed.

23. Remove Retaining Ring (

), Washer (

), Seal (

Lantern Ring (

), and Seal (

) from the Outlet Body.

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SER 9616-A

Low-Pressure Transfer Pump

Revision (10-98) 6 Alemite Corporation

3. Install O-Rings (

) onto both ends of the Outlet

Body.

4. Install Retaining Ring (

) onto Rod (

IMPORTANT: Make sure the ground side of

Plate (

) contacts Fluid Piston (

5. Install Fluid Piston (

) [segmented side ﬁrst], Gasket

(

), and Plate (

) [ground side ﬁrst] onto the bottom

of the Rod.

6. Install Nut (

) 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.

7. Install the Rod assembly into the bottom of the Outlet

Body.

• Position the Fluid Piston ﬂush with the bottom of the

Body.

8. Install Washer (

), O-Ring (

), and Air Piston (

)

(observe THIS SIDE UP] onto the Rod.

9. Install Nut (

) 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.

10. Install O-Ring (

) onto the Air Piston.

11. Screw Stop (

) into Cylinder (

) until it seats.

12. Install Pin (

) into the Stop.

• Make sure the Pin does not protrude from either side

of the Stop.

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 (

) and Fluid Piston (

) for fatigue

cracks.

• Replace as necessary.

4. Inspect Rod (

) 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 (

) into Seat (

Fill the Seat 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.

Outlet Body

1. Install and seat Seal (

) [stem end ﬁrst], Lantern Ring

(

) [stepped end ﬁrst], Seal (

) [stem end ﬁrst], and

Washer (

) into Outlet Body (

2. Secure the components with Retaining Ring (

• Make sure the Retaining Ring seats properly in the

groove.

Item No. Description Notes Item No. Description Notes

Clean Oil

10 O-Ring, 2-3/4 " ID x 3 " OD (Lower) Pump Tube Portion 25 O-Ring, 1-7/16 " ID x 1-5/8 " OD

13 Seal, 1/2 " ID x 3/4 " OD 30 O-Ring, 1-1/4 " ID x 1-3/8 " OD

15 Seal, 1/2 " ID x 7/8 " OD 33 O-Ring, 1-15/16 " ID x 2-1/8 " OD

Magnalube-G Teﬂon Grease

7O-Ring, 2-5/8 " ID x 3 " OD 10 O-Ring, 2-3/4 " ID x 3 " OD (Upper) Air Motor Portion

8O-Ring, 3/8 " ID x 1/2 " OD

Coat the Inside Diameter of the Air Motor Assembly

Table 3

Lubricated Components

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Low-Pressure Transfer Pump

SER 9616-A

Alemite Corporation 7 Revision (10-98)

32 31

Weep

Hole

13. Install O-Ring (

) onto the Stop.

14. Install and seat Spring Discs (

) in an alternate

pattern into Valve Body (

• See

Figure 4

for details.

IMPORTANT: Make sure to press O-Ring

(

) fully into the groove of Seat (31).

15. Install and seat O-Ring (30) into Seat (31).

16. Install the Seat assembly [O-Ring upward] into

the Valve Body.

17. Install Ball (29) into the Seat.

18. Install and seat O-Ring (33) onto the groove of

the valve Body.

19. Screw the Valve Body assembly onto the Stop.

• Tighten the Valve Body securely.

20. Install Air MotorAssembly (4)squarely onto the

Body.

• Use care passing the O-Ring.

• Make sure the outlet of the Body orients

properly with the inlet of the Air Motor.

21. Install the Cylinder assembly squarely onto the

bottom of the Outlet Body.

• Use care passing the O-Ring.

22. Install and seat Ring (27) [counter bore end

ﬁrst] onto the Cylinder.

• Rotate the Ring until the holes align with the

Air Motor Assembly.

23. Install Screws (28) that secure the Ring to the

Air Motor Assembly.

• Tighten the Screws evenly and securely in a

crisscross pattern.

24. Screw Bushing (12) [with thread sealant] into

the Outlet Body.

• Tighten the Bushing securely.

Air Motor Assembly

25. Screw Shut-Off Valve (3) [with thread sealant]

into the Air Motor Assembly.

• Tighten the Shut-Off Valve securely in the

position required.

26. ScrewAdapter (2) onto the Shut-OffValve [with

thread sealant].

• Tighten the Adapter securely.

27. Install Air Coupler (1) onto the Adapter.

Figure 4 Pump Tube Assembly - Section View

Refer to Figure 2 Parts List

for Parts Identification

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SER 9616-A Low-Pressure Transfer Pump

Revision (10-98) 8 Alemite Corporation

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 [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 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.

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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Low-Pressure Transfer Pump SER 9616-A

Alemite Corporation 9 Revision (10-98)

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 1. Product source empty 1. 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 Outlet Body

(11)

1. Damaged Seal (15)

2. Damaged Rod (18)1. Replace Seal (15)

2. Inspect Rod (18) and replace as necessary

Product leakage visible at

bottom of Outlet Body (11)1. Screws (28) not sufﬁciently tight

2. Damaged O-Ring (10)1. Tighten Screws (28) into Air Motor

Assembly (4)

2. Separate Cylinder (26) from Outlet Body

(11) and replace O-Ring (10)

Air leakage at weep hole in

Outlet Body (11)Damaged Seal (13) Replace Seal (13)

Product leakage visible

between Cylinder (26) and

Valve Body (34)

1. Stop (23) not sufﬁciently tight into

Valve Body (34)

2. Damaged O-Ring (24)

1. Tighten Stop (23) into Valve Body (34)

2. Separate Valve Body (34) from Stop (23)

and replace O-Ring (24)

Internal Leaks

Pump does not prime or

cycles continuously, or

slowly (once or twice/hour)

1. Foreign material between Ball (29)

and Seat (31)

2. Foreign material between Plate (22)

and Fluid Piston (20)

3. Worn or damaged Ball (29)

4. Worn or damaged Seat (31)

5. Worn or damaged O-Ring (7)

6. Worn or damaged Cylinder (26)

7. Worn or damaged Plate (22)

8. Worn or damaged Fluid Piston (20)

Locate and eliminate source of foreign

material.

Disassemble pump tube, clean, inspect, and

replace worn or damaged components

Changes Since Last Printing

Changed Contents of Repair Kit 393627

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SER 9616-A Low-Pressure Transfer Pump

Revision (10-98) 10 Alemite Corporation

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