Introduction Thank you for purchasing an Alemite 3575 series Control Handle complete with mechanical meter. It has been designed to accurately dispense, measure and control flow of engine oil, gear oil, automatic transmission fluid, and anti-freeze/anti-boil fluids. Please read and retain this instruction manual to assist you in the operation and maintenance of this quality product. General Information This manual assists you in operating and maintaining your new oil control handle, and the information will help you ensure many years of dependable performance with trouble free operation. Please take a few moments to read through this manual before installing and operating your new oil control handle. If you experience problems with this product, refer to the troubleshooting sections of this manual. If you require further assistance please contact your local Alemite distributor or authorised Alemite service center. Important Information Oil Control Handle with Mechanical Meter Caution Do not point nozzle at yourself or anyone else. Do not exceed pressure rating of any component installed in system. Install an adequate pressure relief valve for operator safety. Operating pressure: 0-200 psi (0-13.79 bar) Line pressure between pump and the control handle trigger valve must not exceed 1,500 psi (103 bar). Do NOT modify the auto non drip nozzle. Failure to comply could result in minor or moderate injury. Part number 3575-A 3575-B 3575-C 3575-D Figure 1 Oil control handle and mechanical meter (Model 3575-A shown) Description 3575-A Quarts meter with rigid extension Read This Information Carefully Before Use. Your safety is important to us. Read and follow all safety instructions. Some of these instructions "Cautions" alert you to the potential for personal injury. "Notices" throughout this manual advise of potential practices or procedures which may cause damage to your equipment. Do not install in a rigid pipe in-line system. Do not install with a shut-off valve on the outlet side of the meter. Damage may occur to the housing cover. Ensure all operators have access to adequate instructions about safe operating and maintenance procedures. 3575-B Quarts meter with flexible extensions 3575-C Liters meter with rigid extension 3575-D Liters meter with flexible extension. Form 671086 167 Roweland Drive, Johnson City, Tennessee, 37601 www.alemite.com SER 3575-A Initial release (10-15)
Mechanical Meter Oil Control Handle Operation SER 3575A Do not strike oil control handle if it fails to operate. Refer to troubleshooting guide or return unit to nearest authorized service center. Before each use check all hoses for signs of wear, leaks or loose fittings. Tighten all fluid connections regularly and replace weak or damaged hoses. Before attempting any repairs or maintenance of product disconnect air supply from oil pump, release oil line pressure by pressing lever on oil control handle. 50 44 42 To latch the handle first press the lever (40) followed by push button (37). To release latch simply press and release lever (40). The top accumulative register will record the total volume of oil passed through the meter. The bottom register is a reset-able batch total, which can be reset by pressing the reset button. Maintenance Caution Assembly Use Teflon tape (or suitable thread sealant) when connecting the oil control handle to an oil hose. Do not perform maintenance with air supply connected. Do not perform maintenance with fluid inside handle under pressure. Failure to comply may result in minor or moderate injury. Outlet Nozzle The outlet nozzle can be fitted either in line (forward) or on the outlet port pistol style located under the handle. The long outlet tube should be used for the in line option. The short adaptor (44) should be used with the outlet nozzle assembly (50) taken off the long outlet tube when using the pistol style option (see fig. 2). Use threaded plug supplied to seal outlet port not in use. Outlet Nozzle Operation When fluid flows through the handle the outlet nozzle will automatically open. When the fluid flow stops the outlet nozzle will automatically shut. Figure 2 Control meter showing three alternate pistol-style configurations Inspect your oil control handle daily for any signs of damage. Replace any damaged parts or components as required. Control Handle Disassembly Use a clean bench to carry out maintenance. 1 Remove the oil hose from the control handle inlet swivel (33). 2 Unscrew and remove swivel (33) washer (32) and O-ring (31) from the control handle inlet. Clean or replace the strainer (35) and O-ring (34). 3 Slide off the handle sleeve (27). 4 Remove valve spring (30), valve seal assembly (29) and plunger (28). 2
SER 3575A Lever And Valve Removal 1 Using a 2.5 mm Allen key, remove the 2 handle screws (36). Caution Maintain control of swivel. Swivel is under spring tension. Failure to comply may result in minor or moderate injury. 2 Remove lever (40). 3 Remove the backup ring (22), O-Ring (23), then push the valve cam (24) from the handle body (26), and remove O-Ring (25). Control Handle Reassembly 1 Clean and inspect all parts. Replace any suspect, worn or damaged components. Lightly lubricate the valve cam (24) before assembly. 3 Replace the valve cam (24) into the body (26). Note the orientation shown on the assembly drawing. Fit the second O-Ring (25) and backup ring (22). 4 Slide lever assembly (40) into position and replace the two Allen screws (36). (Use thread locker or similar sealant). 5 Replace plunger (28). End hole in plunger must face meter. 6 Assemble the valve seal assembly (29), and spring (30) then replace into the handle body. Install spring, small end first. 7 Replace handle sleeve (27). 8 Replace washer (32), O-ring (31) swivel assembly (33) and screw firmly into place (Use thread locker or similar sealant). After assembly ensure handle latch operates correctly. Mechanical Meter Oil Control Handle 2 Place O-Ring (23) onto valve cam (24). Cut out section in middle of valve cam (24) must face inlet swivel (33). 3
Mechanical Meter Oil Control Handle Meter Disassembly 1 Remove rubber boot (1). 2 Unscrew the 4 x Phillips head screws (7), from the underside of the handle body (26) and remove register assembly (4). 3 Using 4 mm Allen key remove 4 screws (43) from the underside of the handle body (26). Take care when removing register housing as the outlet shaft (12) and assembly are also removed. 4 Remove register housing (6) assembly. 5 Remove gearbox housing (18) assembly. 6 Remove rotors (19, 20). 7 Clean and inspect all parts. Replace any suspect, worn or damaged parts. Gear and O-Ring replacement (register casting) 1 Pull bevel gear off the shaft (5) from inside register housing (6). 2 Remove gear (13), circlip (11), washer (10), O-Ring (9) and shaft (12) from the underside of register housing. 3 Assembly is a reversal of disassembly. Facia Replacement 4 Remove register assembly (4) and remove the register bracket clip (3). Use all new parts when reassembling the gear and shaft assembly. Refer to Meter Disassembly Parts A and B. 6 Assembly is a reversal of disassembly. Clean all components prior to assembly. Meter Reassembly 1 Replace rotors (19, 20) into body casting (26) (see fig 3 for correct positioning). Turn rotors by hand to confirm correct assembly. If rotors do not turn freely. (refer to fig 3 for correct rotor position). 2 Fit O-Ring (21) to the handle body (26). 3 Fit gears (15,16,17) into gear box (18). 4 Replace O-Ring (14) on gear box housing (18) and position gearbox assembly on top of handle body (26). Gears are marked in order of assembly 1, 2 and 3. Gear shaft (12) on register housing assembly (23), must be located through gear 2 (16) inside gearbox and fitted into location hole in gearbox housing (18). 5 Replace register housing assembly (6) on top of gearbox housing assembly (18). 6 Replace 4 Allen head screws (43) and screw the meter assembly together. 7 Fit bevel gear (5) inside the register housing (6). 8 Fit register assembly (4) into register housing (6) and replace 4 x Phillips head screws (7). 26 19 SER 3575A Check correct operation of rotors by latching lever and apply low pressure air into oil inlet. Meter should register flow. 20 Figure 3 Correct rotor position 5 Remove facia (2). 4
SER 3575A Mechanical Meter Oil Control Handle Figure 4 Model 3575 Series Control Handle (Exploded view) 5
Mechanical Meter Oil Control Handle SER 3575A Spare Parts List Item no. Part no. Description Quantity Item no. Part no. Description Quantity 1 393814-7 Mechanical Boot (STD) 1 25 O-ring 1)2) 1 2 Fascia (Liters) 1 26 Body, Handle 1 2 Fascia (Quarts) 1 27 Sleeve, Handle 1 3 Bracket Clip, Register 1 28 Plunger 1) 1 4 393814-6 Register Assembly 1 29 Seal 1)2) 1 5 Gear, Bevel (Quart/Liter) 1) 1 30 Spring, Valve 1)2) 1 6 Housing, Register 1 31 O-ring 1)2)3) 1 7 Screw 1) 4 32 Washer 1)2)3) 1 8 Boss, Brass 1) 1 33 393814-3 Swivel (NPT) 3) 1 9 O-ring 1) 1 34 O-ring 1)2)3) 1 10 Washer 1) 1 35 Strainer 1)2)3) 1 11 E-Clip 1) 1 36 Screw, Countersink 1)2) 2 12 Shaft, Outlet 1 37 Button, Push 1 13 Gear L4 (Liter) 1 38 Button, Spring 1) 1 13 Gear Q4 (Quart) 1 39 Trigger Guard 1 14 O-ring 1) 1 40 Lever, Latching 1 15 Gear L3 (Liter) 1 41 Plug, Lever 1) 1 15 Gear Q3 (Quart) 1 42 Plug, 3/8 1 16 Gear L2 (Quart), 2 Liter 1 43 Screw 1) 4 17 Gear L1 (Quart), 1 Liter 1 44 Adaptor (Pistol Style) 1 18 Housing, Gearbox 1 45 Extension, Flexible 5) 1 19 Oval Gear and Pinion 1 46 Adapter 4) 1 20 Gear, Oval 1 47 Olive 4) 1 21 O-ring1) 1 48 Compression Fitting 4) 1 22 Ring, Backup 1)2) 1 49 Extension, Rigid 4) 1 23 O-ring 1)2) 1 50 Outlet Nozzle Assembly 4),5) 1 24 Cam, Valve 1)2) 1 Repair kits Part no. Note Description Notes 393814-1 1) Kit, Major Service 393814-2 2) Kit, Valve Service 393814-3 3) Kit, Swivel Assembly (NPT) Includes items on Figure 4. 393814-4 4) Kit, Rigid Extension 393814-5 5) Kit, Flexible Extension 6
SER 3575A Mechanical Meter Oil Control Handle Troubleshooting Trouble Cause Solution Meter not accurate Flow rate not correct Adjust flow rate to 1-30 l/min (0.26 8 US gal/min) a) Blocked strainer a) Clean or replace strainer No fluid passing through the meter b) Dirt particles jamming the rotors b) Dismantle meter assembly and clean (refer to meter disassembly) c) Damaged plunger seal c) Replace damaged plunger seal a) Damaged register assembly (4) a) Replace register assembly The meter is not registering fluid b) Replace complete gear set, also replace (12) shaft output b) Damaged gear or gears (5,13,15,16, 17) and (9) O-ring. Constant oil leak from the nozzle Damaged plunger seal (29) Replace plunger seal (check for damage) Intermittent drip from the nozzle particles, replace if necessary. Dirt in the nozzle (50) Remove the nozzle and blow out any dirt Oil leak from the lever assembly area Damaged o-rings (23, 25) Replace damaged o-rings Oil leak from between the body handle Damaged o-rings (21) and housing gear box Replace damaged o-rings Low flow rate Blocked strainer (35) Replace strainer Oil leaking from the swivel inlet Damaged o-ring or swivel Replace swivel Specifications Accuracy + - 1% (of Reading) Swivel Inlet 1/2 NPT Flow Range 1-30 l/min (0.26 8 US gal/min) Outlet 3/8 Operating Pressure 0-13.79 Bar / 0-3447 kpa / 0-200 PSI Maximum Pressure 103.50 BAR / 10350 kpa / 1500 PSI Operating Temperature: -10 to 55 C (14 to 131 F) 1Bar/ 100 kpa / 14.4 PSI @ 12 l/min (3.2 US) Pressure Loss gal/min) with calibration fluid (6 Centipoise Wetted Parts: Aluminium, Acetal, Steel, Nitrile Rubber Viscosity) without extension Weight 1.16 kg ( 2.55 lbs) Fluid Compatibility: Engine Oil, Diesel Oil, Automatic Transmission Fluid, Anti-freeze / Anti-Boil Mixture. (Maximum Viscosity SAE140) Dimensions: 25.8 cm (10 inch) Long x 9.5 cm ( 3.7 inch) High, x 11 cm (4.33 inch) Wide (Dimensions without extension) 7
Mechanical Meter Oil Control Handle SER 3575A J U U Bob Hoefler Robert Hoefler Director Product Development and Product Engineering St. Louis, MO 8