. Service Guide 318450-4 ALEMITE® Differential Air Motor Description ‘The differential air motors included within this service guide power a variety of low ratio pumps. These motors vary depending on the mode! of pump to which they attach, See Figure 2 for details. ‘These air motors are divorced from the product being pumped. IMPORTANT: These air motors are not available to be purchased separately. Air inlet Air Exhaust Specifications Piston ike ie Diameter Stoke [Piston Ara] ic age | MB In Cm | int | Cm? oh pinexa|saxi0a| va [08 [ia-wrR@| The efecive piston area of differential sr motor equal one-half the aa ses ofthe piston. 8 Foc information othe maxioum ai presere for these aur motors, please rele to the pumps Service Guide ‘Table 1 Differential Air Motor Specifications Figure 1_ Differential Air Motors for 7216 Series, 7222-B4, Alemite Corporation PO Box 473515, Charlotte, North Carolina 28247-3515 www.alemite.com CCorsigh © 2000 by Alemite Corporation SER 318450-4 “Tic documen contains conidental infomation tht ithe propery of Akemite Corporation 997873 ‘ands not be coped ed. o eaclosed1 ohrs mid! Capes wien peraseon, Revision (4-00)Te Dem my udless 336507 TeHon Pacleims Coun re moron BIB WSBCinel Tax 393635 Differential Air Motor SER 318450-4 3345“ Tiek o +) Ce g ‘tines Stoel Cater in (eppteaio teat pumps exe 7200.01) rate ana 7222-84 me59 ‘7216-3 ond 7380-01 Figure 2. Differential Air Motors for 7216 Series, 7222-B4, and 7880-CI Pumps - Exploded View Alemite Corporation Revision (4-00)Differential Air Motor SER 318450-4 Hem) part No. Description wy Notes Part tem 1 | 337488 | Cylinder Assembly 1 01 © % Plate tla 10735) 3 | XI71001-43| O-Ring, 1/4 "ID x 7/16 "OD T [esa] Qyofl0imaKit | x171000.29 @) 4 ‘Adapier ase XIT1001-43.@) 5 Gasket (Copper) 1 Tea x171009-35 (17) 6 | 31878 | Spacer a 318457 a) 7 [170735 _ | Nut Blasio Stop, 832 3 le 318469 (9) & | 318795 | Washer, 0.1345 "Thick i aisa1 (8) 9 | 318796 | Packing (Rubber) ile 3184731 @4) 10 | 318457 | Washer, 0.095" Thick 1 318475 @0) 11 | 318789 | Washer t 318485 (12) 12 | at8i8s | Spacer i sis781 (4) 13 | 318783 | Spring ile sis) 14 [aie7ar | Washer i 318783 (3) 15 [ 319314 | Screw, 832K I® 3 le 318785 @2) 16 Gasket (Aluminum) 3 fe al Oyof30inaKit | 318799 (1) 17 | X171009-35| O-Ring, -I5N6"IDx218°OD | 1 leaal Qyofl0inaki | 318795 18 | 318471 | Packing, Block-V (Rubber) ile 318795 @) 19 | 318469 | Washer, Back-Up (Fiber) ile 318859 @) 20 | 318475 | Adaptor Assembly (w exhaust port) | 1 ee ee 2i | 332266 | Adapter Assembly (wo exhaust port) | 1 sis (16) 22 [ 318785 | Piston Assembly (w/ ste! tube) 1 72164, 7222-4 | 323561 (27) 23 | 332267 | Piston Assembly (w/ stainless steel cube] 1 s2aas (28) 2 | 3184731 _| Adapter 1 326354 (25) 25 | 326354 | Bearing (Brass) 1 332266 @2l) 26 Tube 1 7216-8, T880-C1 | 332267 @3) 27 | 323561 | Rod 1 333388 (©) 28 [324481 | Connector (w/ nylon inser) 1 uss (26) “Additional Kit Items Applicable to the Famp Tube Assembly 337488 (1) a [318859 | Pin, Cotter, V8 "Dia. x KIM "(SS)__| I fo | Broept 7880-C1_| sx =) | 17100029] O-Ring, 1-5/8 "1D x2 "OD. tle | mie mmana | ums — @ © [333388 | Gasket (Stainless Steel 1 fe _ [721683, 4, 722-B4 Tagen Prt amr ef an (rin ic) sent mabe separately AA designates srepicktem SS Stns Sel Repair Kits PartNo. | Kit Symbol Description Notes 395633 . Kit, Major Repair (Includes tube of 398030 viscous "H" Tubrican}) 393850 Zs Kit, Air Valve Conversion Plate and Adapter) See Figure 3 393634 ‘| Kit, ORing Replacement for Air Valve Alemite Corporation @) Revision (4-00)SER 318450-4 IMPORTANT: Prior to performing any maintenance procedure, the following safety precautions must be observed. Personal injury may occur. WARNING Release all pressure within the system prior to performing any overhaul procedure. ‘= Disconnect the alr supply line from the motor. + Into an appropriate container, operate the control valve to discharge remaining pressure within the system. Read each step of the instructions carefully. Make sure a proper understanding is achieved before proceeding. Overhaul NOTE: Refer to Figure 2 for component iden- tification on all overhaul procedures. Disassembly Separate Air Motor from Pump Pump Models 7216-4, 7216-3, and 7222-B4 1, Clamp the outlet body of the pump horizontally in a soft-jaw vise. 2, Loosen the jam nut that secures the pump tube to the ppamp’s outlet body, if applicable. CAUTION Support the pump tube assembly during removal. Damage to components can occur. Differential Air Motor 3. Unserew the pump tube [with attached components] from the outlet body. 4, Pull on the pump tube fo expose the end of Piston Assembly (22, 23) as required. 5, Remove the cotter pin that secures the Piston Assembly to the rod of the pump tube. 6. Unscrew the pump tube rod from the Piston Assembly. + Rotate the entire pump tube assembly. 7. Loosen the jam nut that secures Adapter Assembly (20, 21). to the pump's outlet body, if applicable. 8. Unserew the pump’s outlet body assembly from the ‘Adapter Assembly Pump Models 7216-B and 7880. 9. Clamp the motor horizontally ina soft-jaw vise at ‘Adapter (24) 10, Unscrew Tube (26) from the Adapter. "CAUTION Support the pump tube assembly during removal. Damage to components can occur. 11. Remove the cotter pin/elip that secures Connector (28) to the rod of the pump tube. 12, Unscrew the pump tube rod (with attached components] from the Connector. + Rotate the entire pump tube assembly. Air Motor Air Cylinder and Valve Assembly 13, Unscrew Cylinder Assembly (1) from Adapter ((20, 24 or 24). 14. Remove the Piston Assembly (Rod) [with attached ‘components] from the Adapter Assembly. 15, Remove O-Ris 1g (17) from the Adapter. 16, Remove Nuts (7) that secure Plate (2) to the Washer and Packing group. ‘+ Remove the Plate. + Remove Screws (15), Gaskets (16), and Spacers (6). 17, Remove O-Ring (3) from the Plate. Revision (4-00) ‘Alemite CorporationDifferential Air Motor 18, Unscrew Adapter (4) from Piston Assembly (22, 23) or Rod (27), 19, Remove Washer (14), Spring (13), Spacer (12), ‘Washers (8, 10, and 11) and Packing (9) from the Adapter, 20. Remove Gasket (S) from the Piston Assembly (Rod). IMPORTANT: Do not disassemble the Piston Assembly. Components are secured at the factory with Loctite 277. Unscrew Connector (28) from the Rod as required Adapter Assembly Pump Models 7216-4, 7216-S3, and 7222-B4 SER 918450-4 Clean and Inspect NOTE: Use the appropriate repair kit for replacement parts. 1, Clean all metal pars in cleaning solvent. The solvent should be environmentally safe. 2. Inspect all parts for wear and/or damage. + Replace as necessary. 3. Inspect the bore of Cylinder Assembly (1) for score ‘marks. ‘+ Make sure the spring is not loose or broken. 4. Inspect the wear surface of Piston Assembly (22, 23 or Rod 27) closely for score marks. + Replace as necessary. Assembly IMPORTANT: Do not separate the adapter {from the tube, Components are secured at the {factory with Loctite 277. The washer between these components is set to float. 21. Remove Block-V Packing (18) and Back-Up Washer (19) from the Adapter Assembly. HINT: Use a small flathead screwdriver. NOTE: Prior to assembly, certain compo- nents require lubrication. Refer to Table 2 for details Adapter and Tube Assembly ‘Pump Models 7216-8 and 7880-Ct 22. Remove Bearing (25), Back-Up Washer (19, and. Block-V Packing (18) from the Adaptec, Them No, iption Description 3] O-Ring, 11D x76 “OD 17 _ | ORing Lisié"iD xan “OD 9 | Packing Te | Packing, Blol-V » | oRing t98"1Dx2"0D ‘Viscous Ht Labricant 1 [ evinder= Bore 9 _| Packing -Oatie Diameter "NOTE: Part umber 398030 «2 ence (57 pa) tbe of Viscous Lnbicant Table 2 Lubricated Components ‘Alemite Corporation © Revision (4-00)Differential Air Motor SER 318450-4 Rofor to Figure 2 Parts List for Parts Identification 18 25 28 26 2 28 gamma a eee 22,23 7216-4, 7216 83,0nd 12204 (iate4 Shown). Figure 3 Differential Air Motors for 7216 Series, 7222-B4, and 7880-C1 Pumps - Section View 5 zg 8 i 2 Revision (4-00)Differential Air Motor Air Motor Adapter Assembly. Pump Models 7216-4, 7216-S3, and 7222-B4 NOTE: If Adapter Assembly (20, 21) was disassembled in err * Install the washer into the adapter. + Tighten the tube (with Loctite 277) into the adapter until it bottoms. ‘Loosen the tube 1/4-tumn. + Make sure the washer floats 1. Install and seat Back-Up Washer (19) and Block-V Packing (18) (lips upward] into the Adapter Assembly. *+ Use care not to distor the Back-Up Washer, 2. Install Piston Assembly (22,23) into the bottom ofthe Adapter Assembly. = Do not allow the eross holes to contact the Block-V Packing, NOTE: If Piston Assembly (22, 23) was dis- assembled in error: *+ Screw the spud (with Loctite 277) [w/o cater pin hole] securely into the top of the piston tube. IMPORTANT: The eross holes are located 5-1/8 "(13 em) from the top of the piston ‘ube, See Figure 2 + Screw the plug (with Loctite 277) securely into the additional spud. + Screw the spud and plug ae verbly (with Loctite 277) securely into the piston tube. 3. Install O-Ring (b) onto the pump’s bushing/packing. screw as applicable. 4, Screw the pump's outlet body assembly securely onto, the Adapter Assembly. + Do not allow the cross holes to contact the packing ‘group. 4. Tighten the jam nut as applicable. Valve Assembly 6.Posi Packing (9) “Top Side” upward, CAUTION Do not switch Washers (8) and (10). Air leakage will ocour. SER 3184504 7.Install Washer (8) onto the top of Packing (9). NOTE: Washer (8) is slightly thicker than Washer (10), £8. Install Washer (10) onto the bottom of the Packing. ‘9, Install and seat the Packing assembly (Top Side frst) ‘onto Adapter (4). 10. Install Spacer (12) onto the Adapter. 1 Install Washer (11) and Spring (13) onto the Spacer. 12, Install each Gasket (16) onto each Screw (15). 13, Install each Serew and Gasket assembly into Washer (AX) and Packing (9). * Rotate the Washer as required. 14, Install Washer (14) onto the Adapter. 15, Install Gasket (5) into the top of Piston Assembly (22, 23) or Rod (27). 16, Serew the Adapter assembly into the Piston Assembly or Rod. + Torque the Adapter to 20 foot-pounds (27 Nm). 17 Install each Spacer (6) onto the Screws. 18, Install O-Ring (8) onto Plate 2) 19, Install the Plate assembly onto the Serews. 20, Secure the Plate with Nuts (7). * Torque the Nuts from 23 to 27 inch-pounds 26-31 Nm). Adapter and Tube Assembly Pump Models 7216-B and 7880-C1 21, Install and seat Block-V Packing (18) [lips first], Back-Up Washer (19), and Bearing (25) [large diameter first] into Adapter (24), 22, Screw Connector (28) into Rod (27). 23, Install the Rod assembly into the Adapter. Cylinder Assembly 24, Install O-Ring (17) onto the Adapter. 25. Screw Cylinder Assembly (1) onto the Adapter, + Use care passing the Packing and O-Ring Alemite Corporation © Revision (4-00)SER 318450-4 Attach Air Motor to Pump Tube Installation Refer to the Pump SER Service Gulde for details. Bench Test and Operation Par Namber Doctor Refer tothe Pump SER Service Guide fordewis. [aetna | Maina SpraReqalr & Gage Contnnion 304d | Man Spar Check the motor for air leakage. Ifthe motor leaks, refer to the Troubleshooting Chart for details Differential Air Motor ‘Additional items that should be incorporated into the air piping system are Histed in Table 3 SMIGOEB | Regultor end Gauge $50k2 | Labrcsor® ‘Table 3 Air Line Components * Although the air motor is lubricated atthe Factory, the life of the motor can be extended with the use ofa lubricator. Troubleshooting Chart Indications Possible Problems Solution ‘Air Motor and/or Pump does not eyele 1. Ineufficient air pressure 2. Aie motor jammed andlor cont components Increase air pressure 2. Rebuild air motor 4. Damaged spring in Cylinder Assembly (1) | 3. Replace Cylinder Assembly C1) 44 Damaged Spring (13) 4. Replace Spring (3) 5 Pamp tube jammed and/or contains oose | 5. Rebuild pump tbe components External Leaks ‘Ar leakage at bottom of 1. Worn or damaged O-Ring (17) 1, Replace O-Ring (17) Colinder Assembly (1) 2. Worn or damaged Cylinder Assembly (1)_| _2. Replace Cylinder Assembly (1) ‘Air leakage at exhaust |. Worn or damaged Packing (9) Worn or damaged Block-V Packing (18) ‘Worn or damaged Piston Assembly (22, 23) or Rod @7) - Replace Packing (2) Replace Block-V Packing (18) Replace Piston Assembly (22, 23) or Rod @7) 4, Worn or damaged O-Ring (3) 4, Replace O-Ring @) ‘5. Worn or damaged Adapter (4) 5. Use Conversion Kit 393550 6, Worn or damaged Gasket (5) 66. Use Major Repair Kit 393633, 7. Worn or damaged Gasket (16) 7. Use Major Repair Kit 393633, Changes Since Last Printing ‘Changed Components to Major Repaic Kit 393633 Revision (4-00) ‘Alemite Corporation