Alemite 8540-B Service Manual
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Alemite 8540-B Service Manual

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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
Piston Diameter x Stroke
Inches
Centimeters
3 x 1-5/8
76.2 x 41.3
* With pressurtrol, [100 psi (6.9 Bars) without pressurtrol] For information
on the air motor, refer to SER 324400-5
Pump tube
Max. Material Pressure
Material Outlet
psi
"
7500
3/8
NPTF (f)
* For detailed information, refer to Figure 4
670763
SERVICE GUIDE
High-Pressure Lubricant Pump
Max. Air Pressure *
Air Inlet
psi
"
1/4
NPTF (f)
200
Max. Delivery/ Minute
(Approximate)*
Bars
Ounces
Grams
517
32
909
167 Roweland Drive, Johnson City, Tennessee 37601
Figure 1 Pump Models 8540-B and 8549 Series
Bars
Container Size
Pump
13.8
lbs
Model
8540-B
120
8549-B1
400
8549-C
Displacement per
Cycle
in
cm
3
3
0.277
4.54
Alemite , LLC
www .alemite.com
Model 8549-B1 Shown
X (X
)
1
Bung
Adapter
kgs
Inches
Cm
50
27-3/4
70.5
37 (35) 94 (89)
●
180
37
94
8540-B
8549-B1
8549-C
y
Inches
Cm
38-1/8
96.8
47-3/8 120.3
SER 8540-B
Revision (12-14)

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Summary of Contents for Alemite 8540-B

  • Page 1 [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.
  • Page 2 SER 8540-B High Pressure Lubricant Pump Figure 2 High-Pressure Lubricant Pump Models 8540-B and 8549 Series- Exploded View...

  • Page 3: Repair Kits

    High Pressure Lubricant Pump SER 8540-B Numeric Order Item Part No. Description Notes Part # Item # 170292 Screw, Machine 8-32 x 1-1/4″ Long 43748 321085 Muffler 51017 See SER 324400-5 Motor Assembly, Air 131168 327033 Adapter, 1/4″ NPTF (m)

  • Page 4: Conversion Kit

    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.

  • Page 5: Performance Chart

    180 kg 338994 338984 Table 3 Pump Models 8540-B and 8549 Series Accessories 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.
  • Page 6 SER 8540-B High Pressure Lubricant Pump...
  • Page 7 High Pressure Lubricant Pump SER 8540-B IMPORTANT: Prior to performing any maintenance procedure, the Pump Tube (Outer Components) following safety precautions must be observed. Personal in}ury may occur. 6 Rotate the Primer Body. • Use a large wrench or other suitable tool.

  • Page 8: Clean And Inspect

    SER 8540-B High Pressure Lubricant Pump Pump Tube (Inner Components) 4 Closely inspect the mating surfaces of all components for any im- perfections. Ensure a smooth and clean contact is obtained when 23 Remove Pin (16) that secures Coupling (15) to the air motor rod.
  • Page 9 High Pressure Lubricant Pump SER 8540-B 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).

  • Page 10: Operation

    SER 8540-B High Pressure Lubricant Pump CAUTION 41 Screw Adapter (10) into the Air Motor. • Install the outer component assembly onto the inner assembly Tighten the Adapter securely. • with care. Damage to Seal (29) can occur. Make sure to orient the Adapter properly.

  • Page 11: Applied Standards

    High Pressure Lubricant Pump SER 8540-B Declaration of conformity as defined by Machinery Directive 2006/42/EC WARNING This is to declare that the design of the low pressure fluid lubricant Should leakage occur anywhere within the system, pump complies with the provisions of directive 2006/42/CG disconnect air to the motor.

  • Page 12: Troubleshooting Chart

    SER 8540-B High Pressure Lubricant Pump Troubleshooting Chart Possible Problems Solution 3 Pump Indications 1. Inspect air motor and rebuild or Pump does not cycle 1. Air motor not operating properly replace as necessary 2. Pump tube jammed and/or contains 2.

This manual is also suitable for:

8549-c8549-b1

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