Val-Tex Easy Lube 40-70 Operating Manual Download

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Service Guide

SER 8540-A1

8540-A1
8541-5

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

397987

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

Revision (7-98)

Air

Inlet

Figure 1

Pump Models 8540-A1 and 8541-5

Model 8541-5 Shown

Description

The major components of high-pressure pump assembly

models 8540-A1 and 8541-5 consist of a(n):

• air-operated motor
• lubricant pressure controller (pressurtrol)
• double-acting reciprocating pump tube
• cover assembly and follower plate
• control valve, z-swivel, hose, & dolly (Model 8541-5)

The pressurtrol minimizes material pressure drop that

occurs when the pump cycles. Refer to SER

319800-1

for

details.

Pump Assembly

The high-pressure (70:1 ratio) pump assembly included

with each model is designed to deliver a range of greases
[up to NLGI # 3] and operates directly from an original
120-pound container.

Models 8540-A1 and 8541-5

Model 8540-A1 is stationary. It contains a cover and

follower plate. Model 8541-5 is portable and includes a
dolly, control valve, z-swivel, and delivery hose.

Specifications

Air Motor

Pump Tube

Piston Diameter x Stroke

Air Inlet

Max. Air Pressure *

Inches

Centimeters

psi

Bars

3 x 1-5/8

7.6 x 4.1

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

Material

Outlet

Max. Material

Pressure

Max. Delivery/

Minute

(Approximate)*

Displacement

per Cycle

psi

Bars

Ounces

Grams

3/8 " NPTF (f)

7500

517

909

0.277

4.54

* For detailed information, refer to Service Guide SER

8540-B

Table 1

Pump Assembly Specifications

High-Pressure Pump (Stationary and Portable)

Pump

Model

Cover and

Follower

Control Valve,

Z-Swivel, Hose,

and Dolly

Width x Height

(including container)

Inches

8540-A1

15 x 39-3/4

38 x 101

8541-5

20-1/4 x 43-1/4

51 x 109

Summary of Contents for Easy Lube 40-70

Page 1: ...se of 40 70 Pail Adapter Service Instructions and Parts List for High Pressure Pump Model 8540 A1 Service Instructions and Parts List for Air Motor Model 324400 5 Service Instructions and Parts List for Pump Tube 331378 Service Instructions Parts List for Volume Control Valve 6438 Drawing and Parts List for Canister and Dolly Additional parts listing ...

Page 2: ... units come equipped with a 15 000 PSI gauge Gauge Guard dual swivels control handle 10 foot 3 8 inch I D high pressure grease hose and whip end hose with giant buttonhead coupler Fully automated with no manual activation required When pumping Valve Flush remove the follower plate L il Greaser Model 5 70 Easy Lube Model 10 70 Easy Lube Model 40 70 The carrying handle makes this compact portable gu...

Page 3: ... pail adapter prior to inserting the pail A Open the pail of lube sealant and place it in the bottom of the canister B Insert the follower plate into the lube sealant can C Clamp the canister lid down by tightening down the knurled nuts on the three thumb screws D Secure the latches by engaging them into the strike 3 To Pump Valve Flush NOTE See the instructions for use of the 40 70 pail adapter p...

Page 4: ...ws from the end of the hose 2 Connect to the fitting and begin injecting into the valve 3 After the pail is approximately half empty please refer to the Instructions for use of 40 70 Pail Adapter Dispose of any expelled material properly Periodic Maintenance 1 Refer to service instructions for model 8540 A1 ...

Page 5: ...f Val Tex lube sealant the pail should fit down inside the centering ring and rest on the bottom of the pump canister 2 When the pail is about half empty it should be removed from the canister and the centering ring turned over so that the pail is sitting elevated 3 inches off the bottom of the canister Valve Flush pails should always be loaded in the half empty position without a follower plate ...

Page 6: ...tio pump assembly included with each model is designed to deliver a range of greases up to NLGI 3 and operates directly from an original 120 pound container Models 8540 A1 and 8541 5 Model 8540 A1 is stationary It contains a cover and follower plate Model 8541 5 is portable and includes a dolly control valve z swivel and delivery hose Specifications Air Motor Pump Tube Piston Diameter x Stroke Air...

Page 7: ...ber 5 7 6 11 14 To Item Number 3 Apply Thread Sealant Here Apply Thread Sealant Here Apply Thread Sealant Here 4 5 2 2 8 9 10 12 13 15 3 NOTE Coupler points upward on Model 8540 A1 Apply Loctite 222 Here Figure 2 High Pressure Lubricant Pump Stationary and Portable Models 8540 A1 and 8541 5 Exploded View ...

Page 8: ... 14 Legend Part numbers left blank or in italics are not available separately Assembly NOTE Refer to Figure 2 for component identification on all assembly procedures CAUTION Select a clean environment for all assembly proce dures Prevent contamination from foreign mate rial Damage to components can occur Pump Assembly and Cover IMPORTANT Make sure to remove the pro tective cover from the inlet of ...

Page 9: ...7 Screw either end of Material Hose 2 into the Adapter with thread sealant Tighten securely 8 Screw the 1 2 27 end of Z Swivel 5 with thread sealant into the Material Hose See Figure 3 Tighten securely 9 Screw the opposite end of the Z Swivel with thread sealant into Control Valve 4 Tighten securely 10 Test Prime the Pump assembly Refer to Service Guide SER 8540 B for details Item No Part No Descr...

Page 10: ... product from entering the pneumatic portion of the motor Product is distributed through an outlet in the air motor base See Figure 1 Pump tube separation requires that the pump tube with attached components be unthreaded from the base of the air motor Models 324400 2 324400 4 and 324400 5 The difference between the models in the 324400 series air motors is illustrated in Figure 1 The obsolete low...

Page 11: ...SER 324400 5 Air Motor Revision 10 02 2 Alemite Corporation Figure 2 Air Motor Model 324400 5 with High Pressure Pump Tube Adapter Exploded View ...

Page 12: ... 2 5 16 ID x 2 1 2 OD 1 317529 33 19 Body 1 320727 24 20 Gasket 1 320731 20 21 398439 Valve and Seat Assembly w Gasket 1 320736 25 22 171636 Screw 10 32 x 3 8 4 320737 32 23 171009 29 O Ring 1 9 16 ID x 1 3 4 OD 1 320745 14 24 320727 Inlet Body 1 320746 35 25 320736 Shuttle 1 320748 11 26 330842 Spring Valve Retaining 1 320749 9 27 330843 Retainer Valve 1 321082 8 28 337471 Cap Toggle Stepped 2 32...

Page 13: ...SER 324400 5 Air Motor Revision 10 02 4 Alemite Corporation Figure 3 Additional Kits for Air Motor Model 324400 Series Exploded View ...

Page 14: ...737 Toggle 2 320737 32 36 Seal 0 437 ID x 0 687 OD 1 320971 41 37 Ring Lantern 1 321082 8 38 Seal 0 437 ID x 0 937 OD 1 321457 31 39 Washer 1 321458 f 40 51017 Gasket 0 815 ID Aluminum 1 327329 19 41 320971 Pin 1 330842 26 42 320724 Cap Toggle Smooth 1 Model 324400 2 4 330843 27 Kit Items Applicable to Models 324400 2 and 324400 4 337093 b a O Ring 1 ID x 1 3 16 OD 2 These lower pack ing group com...

Page 15: ...SER 324400 5 Air Motor Revision 10 02 6 Alemite Corporation ...

Page 16: ...ssembly during removal Damage to components can occur 2 Unscrew the pump tube with attached components from the air motor 3 Pull on the pump tube to expose the coupling 4 Remove upper Pin 41 that secures the air motor Piston Rod to the coupling 5 Unscrew the coupling from the air motor Piston Rod Rotate the entire pump tube assembly 6 Remove the adapter from Body 19 7 Remove O Ring 15 from the ada...

Page 17: ...Body model 324400 2 Optional Procedures 24 Unscrew Elbows 4 from the Cylinder and the Body as required 25 Unscrew Packing Nut 14 from the Body as required Remove O Ring 15 26 Unscrew Adapter 16 from the Body as required Remove O Ring 18 NOTE The Packing Nut and Adapter are staked to the Body in three places Clean and Inspect NOTE Use the appropriate repair kit for replacement parts Make sure all t...

Page 18: ... Lubricant Table 2 Lubricated Components 4 Screw and seat the Packing Nut into Body 19 Stake the Packing Nut to the Body in three places See Figure 5 5 Install and seat V Packing 13 lip side first Leather Washer 12 and Brass Washer 11 into the Packing Nut 6 Install Retaining Ring 10 into the Packing Nut Use internal circlip pliers Valve Seat and Shuttle Assembly 7 Install and seat Gasket 20 and Va...

Page 19: ...SER 324400 5 Air Motor Revision 10 02 10 Alemite Corporation Figure 6 Air Motor Model 324400 Series Section View Refer to Figures 2 and 3 Parts List for Parts Identification ...

Page 20: ...21 Install Plunger 31 drain hole downward onto each Toggle 22 Install Spring 30 into each Toggle Cap 28 or 42 Model Dependent Step 23 Install O Ring 29 onto each Toggle Cap 28 model 324400 5 Install Gaskets f onto Toggle Caps 42 models 324400 2 and 324400 4 CAUTION Make sure each Toggle is centered in the Shuttle and the Plunger before Toggle Cap installation Damage to the Toggle can occur 24 Scre...

Page 21: ... 43 Remove the protective sleeve from the Piston Rod 44 Position Adapter c large diameter upward 45 Install Split Ring d and additional O Ring a into the groove of the Adapter 46 Install and seat the Adapter assembly small diameter first into the Body 47 Install and seat Seal e heel end first onto the Piston Rod and into the Adapter Use the protective sleeve included in the kit Connect Pump to Air...

Page 22: ...uct 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 contai...

Page 23: ...e Cylinder 5 Air leakage between Adapter 16 and Body 19 Worn or damaged O Ring 17 Replace O Ring 17 Air leakage at Toggle Cap 28 or 42 1 Initial tightening of Toggle Cap to Body 19 not sufficient 2 Damaged O Ring 29 Gasket f 1 Tighten Toggle Cap to Body 19 2 Replace O Ring 29 Gasket f Air leakage at Body Inlet 24 1 Initial tightening of Body Inlet 24 to Body 19 not sufficient 2 Worn or damaged O R...

Page 24: ...igure 1 The difference in the length of the pump tubes for the two 12 5 kg models is due to the design of the cover Model 331378 E1 bolts to a cover with a flat design Obsolete Model 331378 F1 uses a cover with a bung adapter See the section entitled Accessories for details Specifications Air Motor Pump Tube Piston Diameter x Stroke Air Inlet Max Air Pressure Inches Centimeters psi Bars 3 x 1 5 8 ...

Page 25: ...98 2 Alemite Corporation Apply Loctite 242 Here 1 2 3 4 5 6 8 9 7 9 10 11 12 13 14 15 16 17 18 6 19 6 20 21 22 23 24 25 26 27 6 28 29 30 31 32 33 34 35 Apply Loctite 222 Here Place Punch Here Figure 2 High Pressure Pump Models 331378 Series Exploded View ...

Page 26: ... 331378 E1 320975 9 337392 1 Tube 9 Long 1 Model 331378 F1 321085 2 337392 4 Tube 12 5 Long 1 Model 331378 H1 321605 13 19 Bearing Brass 1 324400 5 3 20 337391 Retainer 1 324437 35 21 Seal 0 540 ID x 0 914 OD 1 324438 1 33 22 Bearing Brass 1 324438 2 33 23 Gasket Aluminum 1 08 ID 1 324438 7 33 24 337388 Extension 1 324438 5 33 25 317549 Washer Stop 1 324438 8 33 26 Seal 0 282 ID x 0 532 OD 1 32480...

Page 27: ...since 1983 requires 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 procedures outlined in the section entitled Assembly Figure 3 Early Model Pump Tubes Section View Table 2 Pump Model Comparison with Pu...

Page 28: ...t 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 consumption in cubic feet liters per minute right Y axis an...

Page 29: ...Air Motor Packing Group at Pump Overhaul Refer to Air Motor Service Guide for Details Apply Loctite 242 to Ball Stop at Initial Assembly Make Sure Adapter is Flush with Air Motor Base Air Motor Packing Group may Contain Improper Components Check to Ensure Ball Moves a Minimum of 1 8 3 2 mm Pump may not Prime Check to Ensure the O Ring is Installed Follower Plate will not Operate Correctly Do not O...

Page 30: ... Use an appropriate size punch in the hole of the Rod to prevent rotation See Figure 2 4 Remove Primer Disc 31 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 Fo...

Page 31: ...and or damage Replace as necessary 3 Inspect Piston 17 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 imperfections Ensure a smooth and clean contact is obtained when assembled EXAMPLE Place Ball 15 into Piston 17 Fill the Piston with solvent Make sure no leakage occurs Assembly NOTE Prior to assembl...

Page 32: ...nto the bottom of Retainer 20 See Figure 2 14 Install and seat Bearing 22 into the bottom of the Retainer 15 Install Gasket 23 onto the top of Extension 24 16 Screw the Extension Gasket end first into the bottom of the Retainer Do not tighten at this time 17 Install Gasket 6 into the top of the Retainer 18 Install and seat Bearing 19 small diameter first and additional Gasket 6 into the top of the...

Page 33: ...Install and seat Seal 26 heel end first into Valve Body 27 27 Install the Valve Body assembly Seal first onto Rod 29 Make sure the Valve Body assembly seats properly in the Extension 28 Install Follower Tube 33 over the outer tube assembly 29 Install O Ring 34 onto Primer Body 35 30 Install and seat Valve Seat 28 large diameter first into the Primer Body 31 Install and seat Gasket 6 into the Prime...

Page 34: ...ge occur anywhere within the system disconnect air to the motor Personal injury can occur With air pressure at zero 9 Attach a control valve to the outlet hose of the pump 10 Set the air pressure to 100 psi 6 9 Bar 11 Operate the control valve into a container 12 Allow the pump to cycle until the system and grease is once again free of air 13 Shut off the control valve Visually inspect the pump fo...

Page 35: ... tightening of Tube 18 to Adapter 5 not sufficient 2 Initial tightening of Tube 18 to Retainer 20 not sufficient 3 Initial tightening of Extension 24 to Retainer 20 not sufficient 4 Initial tightening of Extension 24 to Primer Body 35 not sufficient 5 Gasket s 6 worn or improperly crushed 6 Gasket 23 worn or improperly crushed 1 Tighten Tube 18 into Adapter 5 2 Tighten Tube 18 into Retainer 20 3 T...

Page 36: ......

Page 37: ......

Page 38: ...sembly 1 See Figure 2 B 12369 6 2 Grip Handle 1 77650 5 3 303087 Knob 3 77736 8 4 Pin Cotter 3 172212 1 4 5 Nut 6 303087 3 6 Washer Lock 6 308725 B4 7 7 308725 B4 Container Assembly w o Decal 1 308726 B4 9 8 Screw 6 310750 4 1 9 308726 B4 Cover Assembly 1 337066 2 10 Seal 1 337438 10 Legend Part numbers left blank or in italics are not available separately designates a repair kit item See Figure 2...

Page 39: ......

Page 40: ......

Page 41: ...T 40 70 Pail Adapter HOSE ASSEMBLY PART NUMBER DESCRIPTION 51541 1 2 Straight Swivel 51543 1 2 Z Swivel 1012 88 2 Hose Adapters S23 8 A8 120 1 2 10 Foot Hose 6438 Control Handle w Bleeder Assembly 47123 47124 301296 Adapter 25 TEE 1 4 Tee 15MGF 15 000 PSI Gauge GC 250 Gauge Guard 16 Straight Swivel 20 Hose 43379 Adapter 6 Giant Buttonhead Coupler OPTIONAL EQUIPMENT PART NUMBER DESCRIPTION SM 7604 ...

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