Alemite 7175-R4 User manual

Service Guide
SER 7175-R4
7175-R4
Alemite, LLC
167 Roweland Drive, Johnson City, Tennessee 37601
www.alemite.com
Copyright © 2011 by Alemite, LLC
This document contains confidential information that is the property of Alemite, LLC
396128 and is not to be copied, used, or disclosed to others without express written permission. Revision (2-13)
NOTE: For Table of Contents and
List of Illustrations, see Page 2.
Description
The major components of the 7175-R4
mobile “Rockcrusher” grease pump consist of a:
• 40 pound (18.2 kg) capacity container
• pressure switch controlled drive motor
• helix arm/blade and helicoid flight
priming mechanism*
• high-pressure control valve with z-swivel
and 10 foot (3 m) hose assembly
The pump delivers 14 ounces (0.40 kg) of
NLGI No. 1 grease [at 70 F (21 C)] each minute.
Heavy fibrous grease is pumped at a rate of
5-1/2 ounces (0.16 kg) per minute.
Pressure Switch
A pressure switch maintains lubricant
pressure between 3500 and 5000 psi
(241-345 Bars). This switch assembly acts as
the on/off switch during control valve operation.
Emergency Bypass System
A pressure relief valve operates as a back-up
to the pressure switch.
* This is a positive-feed design that
dispenses heavy grease at low temperatures.
High-Pressure Grease Pump
Bleed/Prime Assembly
This bleeder allows the pump to be primed for initial start-up.
Figure 1 High-Pressure Grease Pump Model 7175-R4
Specifications
Sump
Capacity Gear Oil
Ounces Liter
32 0.95 SAE 80W-90 (GL-5)
Motor
Size Maximum
Amperage RPM (Full Load) Volts
hp kW
3/4 0.56 8 12,000 120 @ 60 Hz
Table 1 High-Pressure Grease Pump Model 7175-R4 Specifications

SER 7175-R4 High-Pressure Grease Pump
Revision (2-13) 2 Alemite, LLC
Section Page
Description.....................................................................1
Pressure Switch.............................................................1
Emergency Bypass System...........................................1
Bleed/Prime Assembly .................................................1
Specifications.................................................................1
Sump.............................................................................1
Motor ............................................................................1
Preventive Maintenance.................................................3
Overview of Product Flow ...........................................12
Power Train ................................................................12
Valve Body.................................................................12
Pressure Switch Port .............................................14
Emergency Bypass Port........................................14
Bleed/Prime Assembly Port..................................14
Priming............................................................14
Remove and Replace....................................................15
Motor ..........................................................................15
Pressure Switch...........................................................16
Initial Preparation ........................................................17
Pump Overhaul ............................................................17
Breakdown..................................................................17
Container and Accessories....................................17
Helicoid Housing Assembly.................................17
Base Assembly Peripherals...................................17
Pressure Switch and Valve Body Assembly.........17
Additional Base Assembly Peripherals.................18
Motor and Body Assembly...................................18
Gear Train Assembly............................................18
Section Page
Disassembly ............................................................... 18
Planetary Gear Body............................................. 18
Valve Body........................................................... 18
Pressure Switch .................................................... 19
Clean and Inspect....................................................... 19
Gear Train............................................................. 19
Assembly.................................................................... 19
Planetary Gear Body............................................. 19
Pressure Switch .................................................... 20
Valve Body........................................................... 20
Rebuild....................................................................... 21
Gear Train Assembly............................................ 21
Valve Body, Gear Body, and Motor..................... 21
Electrical Connection ........................................... 22
Combine Pressure Switch with Valve Body ........ 22
Initial Test....................................................... 22
Helicoid Housing.................................................. 23
Container and Accessories ................................... 23
Initial Priming................................................. 23
Complete the Rebuild Assembly.......................... 23
Final Priming .................................................. 24
Operation and Adjustments........................................ 24
Pressure Settings Check ....................................... 24
Pressure Switch Adjustment........................... 24
Emergency Bypass Mechanism Adjustment .. 25
Motor Overhaul ........................................................... 26
Disassembly ............................................................... 26
Clean and Inspect....................................................... 26
Assembly.................................................................... 26
Troubleshooting Chart................................................. 28
Table of Contents
Figure Title Page
High-Pressure Grease Pump Model 7175-R4.................1
High-Pressure Grease Pump - Exploded View ...............4
High-Pressure Grease Pump - Exploded View ...............6
Pressure Switch and Valve Body Assembly
Exploded View ...........................................................8
Pressure Switch Assembly - Exploded View................10
High-Pressure Grease Pump Power Train ....................12
High-Pressure Grease Pump Wetted Path.....................13
Figure Title Page
High-Pressure Z-Swivel - Exploded View................... 14
Position of Planetary Gears in Gear Body ................... 15
Electrical Switch Wire Connections ............................ 16
Pressure Switch Assembly - Section View .................. 20
Priming Mechanism, Pressure Switch, and Emergency
Bypass Mechanism Adjustments.............................. 23
High-Pressure Test Gauge Assembly - Model 5287..... 25
Motor - Exploded View ............................................... 27
List of Illustrations

High-Pressure Grease Pump SER 7175-R4
Alemite, LLC 3 Revision (2-13)
Preventive Maintenance
Daily Weekly Monthly Yearly
Wipe Exterior with Clean Cloth 1. Inspect for Product and/or
Oil Leakage
2. Check Sump Oil Level
1. Inspect Hose and all Rubber
Components for signs of Deterioration
2. Tighten all Connections
3. Clean Valve Body Check Valve
1. Change Sump Oil
2. Inspect Motor Brushes
3. Lubricate Front Wheel Bearings (2)
Table 2 High-Pressure Grease Pump Model 7175-R4 Preventive Maintenance Schedule

SER 7175-R4 High-Pressure Grease Pump
Revision (2-13) 4 Alemite, LLC
Figure 2-A High-Pressure Grease Pump - Exploded View

High-Pressure Grease Pump SER 7175-R4
Alemite, LLC 5 Revision (2-13)
Repair Kit
Part No. Kit Symbol Description Notes
398730-2 Kit, Major Repair Includes items on Figures 2-A, 2-B, 2-C, and 2-D
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
1 316896-B4 Cover and Handle Assembly 1 6320-3 (8)
2 Screw, 5/16" -18 x 1-1/4 " 8 11648 (45)
3 Ring, Reinforcement 2 12762 (42)
4 316890-B4 Container, 40 Pound (18.2 kg) Capacity 1 46187 (24)
5 77890 Nut, 1/2 " -13 4 46459 (40)
6Rod 2 48490 (7)
7 Cord, Electrical, 115 V ac, 25 ' long (16-Gauge) 1 Contains 15 A Plug B52752 (9)
8 6320-3 Valve, Control, High-Pressure 1 See SER 6320-3 76724 (21)
9 B52752 Swivel Assembly, 3/8 " OD x 3/8 " OD 1 See Figure 5 76784 (34)
10 317878-10 Hose, Material, High-Pressure, 3/8 " ID (10 ' Long) 1 76895 (13)
11 317108-B4 Handle Assembly 1 76925 (41)
12 Screw, 6-32 x 1/4 " 2 77783 (21)
13 Washer, Lock, 6 2 77890 (5)
14 316997-B4 Bracket Assembly 1 79078 (2)
15 Screw, 8-32 x 5/16 " 2 170246 (12)
16 316898 Gasket 2 170250 (32)
17 Nut, 3/8 "-16 8 170276 (15)
18 Washer, Lock, 3/8 " 13 170345 (36)
19 Setscrew, 3/8 " -16 x 1/2 " 2 170770 (25)
20 172207-1 Washer, Lock, 1/4 " 11 170860 (38)
21 Screw, 1/4 " -20 x 1 " 4 172207-1 (20)
22 316497-3 Support, Rear, RH 1 172207-3 (18)
23 337111 Motor Assembly, Electric (w/o Terminals) 1 See Figure 11 172211-1 (19)
24 Screw, 3/8 " -16 x 1-1/4 " 6 172212-17 (30)
25 Setscrew, 8 -32 x 1/2 " 1 316497-3 (22)
26 316498-3 Support, Rear, LH 1 316498-3 (26)
27 317254 Axle 1 316599 (35)
28 Spacer, 1 " OD x 0.64 " ID 2 316840 (29)
29 316840 Collar, Retaining 2 316878 (46)
30 Pin, Cotter, 1/8 " x 1-1/4 " 2 316880 (6)
31 317255-1 Wheel, 8" Dia. x 2-1/2 " 2 316890-B4 (4)
32 Screw, 6-32 x 3/8 " 2 316894 (44)
33 Clamp, Cable 2 316896-B4 (1)
34 Nut, 6-32 2 316898 (16)
35 Grommet 1 316997-B4 (14)
36 Screw, 1/4 " -20 x 1/2 " 7 317108-B4 (11)
37 318835-B4 Cover and Bracket Assembly 1 317253 (28)
38 Screw, 3/4 " -10 x 1" 1 317254 (27)
39 317279 Caster Assembly, 4 " Dia x 1-1/2 " 1 317255-1 (31)
40 Screw, 3/8 " -16 x 2-1/4 " 2 317278-2 (43)
41 76925 Washer, Lock, 3/4 " 1 317279 (39)
42 12762 Nut, 3/4 " -10 1 317878-10 (10)
43 317278-2 Bracket, Caster 1 318285 (3)
44 Disc 1 318835-B4 (37)
45 Screw, 3/8 " -24 x 2-1/4 " 1 336501 (33)
46 316878 Blade and Helix Arm Assembly 1 337111 (23)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item

SER 7175-R4 High-Pressure Grease Pump
Revision (2-13) 6 Alemite, LLC
Figure 2-B High-Pressure Grease Pump- Exploded View

High-Pressure Grease Pump SER 7175-R4
Alemite, LLC 7 Revision (2-13)
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
47 316874 Shaft and Helicoid Flight Assembly 1 13041 (76)
48 316899 Key, 1/8 " x 3/16 " x 5/8 " Long 1 14623 (75)
49 171001-15 O-Ring, 3/4 " ID x 1 " OD 1 50389 (79)
50 Housing, Helicoid 1 75808 (66)
51 Gear 1 171001-9 (57)
52 Screw, Special, 7/16 " -14 x 1/2 " 1 171001-11 (68)
53 Spacer, 1-1/8 " OD x 0.626 " ID x 0.250 " Thk. 1 171001-15 (49)
54 316887 Gear Train, Intermediate 1 171003-27 (61)
55 Shaft 1 171568 (80)
56 316845 Washer, Thrust, 1-1/4 " OD x 0.437 " ID x 0.218 " Thk. 1
57 171001-9 O-Ring, 7/16 " ID x 5/8 " OD 1 311732 (74)
58 Gasket 1 316152-2 (70)
59 Dipstick 1 316153 (71)
60 316881 Bearing 1 316155 (67)
61 171003-27 O-Ring, 4-7/8 " ID x 5-1/8 " OD 1 316156 (73)
62 Washer, Thrust, 1-5/16 " OD x 0.687 " ID x 0.125 " Thk. 1 316159 (77)
63 316843 Worm and Shaft Assembly 1 316540 (81)
64 316884 Key, 1/8 " x 3/16 " x 1-3/16 " Long 1 316558 (83)
65 320507 Washer, Thrust, 1-1/4 " OD x 0.635 " ID x 0.156 " Thk. 1 316838-4 (82)
66 Screw, 3/8 " -16 x 1-1/4 " 4 316843 (63)
67 316155 Shaft 2 316844 (55)
68 171001-11 O-Ring, 9/16 " ID x 3/4 " OD 2 316845 (56)
69 317979 Seal, Oil 1 316847 (53)
70 Body, Gear 1 316848 (51)
71 316153 Gear, Planetary 2 316874 (47)
72 316883 Gear, Ring 1 316876 (50)
73 316156 Link, Connecting 1 316881 (60)
74 Plug, Pipe, Drain 1 316883 (72)
75 Washer, Lock, 7/16 " 1 316884 (64)
76 Nut, 7/16 " -20 1 316887 (54)
77 316159 Spacer, 1-1/4 " OD x 1.036 " ID 1 316889 (78)
78 Setscrew, 5/16 " -18 1 316892 (62)
79 Gasket 1 316897 (58)
80 Screw, 5/16 " -18 x 2 " 4 316899 (48)
81 316540 Pressure Switch and Valve Body Assembly 1 See Figure 2-C 316980 (52)
82 Base 1 317112 (59)
83 316558 Grommet 1 317979 (69)
320507 (65)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
Repair Kit
Part No. Kit Symbol Description Notes
398730-2 Kit, Major Repair Includes items on Figures 2-A, 2-B, 2-C, and 2-D

SER 7175-R4 High-Pressure Grease Pump
Revision (2-13) 8 Alemite, LLC
Figure 2-C Pressure Switch and Valve Body Assembly - Exploded View

High-Pressure Grease Pump SER 7175-R4
Alemite, LLC 9 Revision (2-13)
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
84 314834 Gasket, 1-1/4 " OD (Copper) 1 17831 (90)
85 314808 Piston and Cylinder Assembly 1 43379 (87)
86 171001-20 O-Ring, 1-5/16 " OD x 1-1/16 " ID 1 47124 (103)
87 43379 Adapter, 1/2 " -27 x 1/4 " NPTF (m) 1 171001-12 (100)
88 316536 Body, Valve 1 171001-20 (86)
89 316544 Gasket 1 302225 (102)
90 17831 Plug, 1/8 " NPTF (m) 1 314808 (85)
91 Gasket, 0.687 " OD (Copper) 1 314821 (104)
92 Seat, Valve, 3/4 " -20 1 314834 (84)
93 Valve, Relief, Emergency Bypass 1 316535 (107)
94 318987 Retainer, Valve 1 316536 (88)
95 Spring, 3 " Long 1 316544 (89)
96 Locknut, 1-1/16 " -20 1 316545 (101)
97 Housing, Spring, 1-1/16 " -20 1 316546 (91)
98 320383 Bolt, Clamp, 9/16 " -18 1 316551 (106)
99 316631 Gasket, 1.03 " OD (Aluminum) 1 316631 (99)
100 171001-12 O-Ring, 13/16 " OD x 5/8 " ID 2 317078 (96)
101 316545 Switch Assembly, Pressure 1 See Figure 2-D 318141 (105)
102 302225 Screw, Bleed Valve, 1/4 " -32 1 318987 (94)
103 47124 Seat, Bleed Valve, 1/4 " -32 x 1/8 " NPTF (m) 1 318988 (95)
104 314821 Adapter, 1 " -20 x 1/8 " NPTF (f) 1 318989 (97)
105 Gasket, 0,92 " OD (Aluminum) 1 318990 (93)
106 Spring, 1-1/4 " Long 1 318991 (92)
107 Valve, Check, Pump 1 320383 (98)
Legend:
Part numbers left blank (or in italics ) are not available separately
designates a repair kit item
Part No. Kit
Symbol Description Notes
393804 * Kit, Switch Repair Includes items on Figures 2-C &2-D
398730-2 Kit, Major Repair Includes items on Figures 2-A, 2-B, 2-C, &2-D
393678 Kit, Repair, Valve Assembly
393679 Kit, Repair, Pressure Switch Assembly Includes items on Figures 2-C &2-D
Repair Kits

SER 7175-R4 High-Pressure Grease Pump
Revision (2-13) 10 Alemite, LLC
Figure 2-D Pressure Switch Assembly - Exploded View
*
*