Alemite 7735 User manual

Service Guide 7735
Alemite Corporation
167 Roweland Drive, Johnson City, Tennessee 37601
www.alemite.com
Copyright © 2003 by Alemite Corporation
This document contains confidential information that is the property of Alemite Corporation
670698 and is not to be copied, used, or disclosed to others without express written permission. Revision 6-03
SER 7735
Figure 1 Medium-Pressure Bulk Grease Pump
Model 7735
Description
The major components of pump model 7735 consist of an air-
operated motor and a pump tube. The air motor connects directly
to the double-acting reciprocating pump tube.
This medium-pressure (10:1 ratio) grease pump is designed to
transfer a range of greases [up to NLGI # 3] from their original
bulk containers to smaller containers.
Mounting
In most cases these pumps connect horizontally to a bulk
container. See Figure 5. The pump includes the male portion of a
3-inch camlock connection for ease in installation.
Material Delivery Hose and Control Valve
The use of the proper size delivery hose and control valve (if
used) is essential to optimize flow rate. A hose that is excessively
long or with too small an inside diameter will restrict product
flow.
Both components must have a pressure rating that allows safe
operation at the maximum anticipated pump pressure.
Air Motor
Pump Tube
Piston Diameter x Stroke Air Inlet / Outlet Max. Air Pressure
Inches Centimeters psi Bars
4-1/4 x 4 10.8 x 10.2 3/4 " NPTF (f) 150 10.3
For information on the air motor, refer to Service Guide SER 323440-4
Material
Outlet
Max. Material
Pressure Max. Delivery/Minute (Approximate)* Displacement per Cycle
psi Bars Pounds Kilograms in 3cm 3
3/4 " NPTF (f) 1500 103.5 73 33 9.2 150.8
* For detailed information, refer to Figure 3
Table 1 7735 Model Series Specifications
Medium-Pressure Bulk Grease Pump

Revision (6-03) 2 Alemite Corporation
SER 7735 Medium-Pressure Bulk Grease Pump
Figure 2-A Medium-Pressure Bulk Grease Pump Model 7735 - Exploded View

Medium-Pressure Bulk Grease Pump SER 7735
Alemite Corporation 3 Revision (6-03)
Repair Kits
Part No. Kit Symbol Description Notes
393667 Kit, Major Repair Includes items on Figure 2-A and 2-B
393530-35 Kit, Seal [includes five (5) of item number 11]
Item
No. Part No. Description Qty Notes Numeric Order
Part # (Item #)
1Motor Assembly, Air 1See SER 323440-4 11828 (4)
2328037 Connector, 3/4 " NPTF (m) 177807 (6)
3328031 Coupler, Air, 1/2 " NPTF (f) 1171006-39 (15)
4Screw, 1/2 " -20 x 2 " 4X171009-2 (16)
5Lockwasher, 1/2 " 4X171009-33 (8)
6Nut, 1/2 " -20 4X171009-35 (9)
7338836 Extension, Outlet, 3/4 " NPTF (m and f) 1172190-35 (11)
8X171009-33 O-Ring, 1-13/16" ID x 2 " OD 1172207-4 (5)
9X171009-35 O-Ring, 1-15/16" ID x 2-1/8 " OD 1323440-D1 (1)
10 338835 Body 1323787 (17)
11 Seal, 1-7/16 " ID x 1-13/16 " OD 1328031 (3)
12 Bearing (Brass) 1328037 (2)
13 Seal, U-Cup, 1-7/16 " ID x 1-15/16 " OD 1338824-3 (13)
14 Washer, 1.93 " OD 1338835 (10)
15 171006-39 Circlip, Internal 1338836 (7)
16 X171009-2 O-Ring, 1/2" ID x 5/8 " OD 3338837 (12)
17 323787 Screw, Cap, Socket Head, 1/2 " -13 x 3 " 3338839 (14)
Legend:
Part numbers left blank (or in italics) are not available separately
Part numbers with an X prefix indicate a quantity of ten (10)
designates a repair kit item

Revision (6-03) 4 Alemite Corporation
SER 7735 Medium-Pressure Bulk Grease Pump
Figure 2-B Medium-Pressure Bulk Grease Pump Model 7735 - Exploded View

Medium-Pressure Bulk Grease Pump SER 7735
Alemite Corporation 5 Revision (6-03)
Repair Kits
Part No. Kit Symbol Description Notes
393667 Kit, Major Repair Includes items on Figure 2-B and 2-A
393666 Kit, Minor Repair (for Lower Tube Assembly)
Item
No. Part No. Description Qty Notes Numeric Order
Part # (Item #)
18 X171000-107 O-Ring, 4 " ID x 4-3/8 " OD 1171130 (36)
19 338838 Adapter, Camlock 1X171000-106 (22)
20 Pin, Roll, 5/32 " x 7/8 " 1X171000-107 (18)
21 338828 Rod, Lower 1X171000-108 (27)
22 X171000-106 O-Ring, 2" ID x 2-1/8 " OD 1171034-7 (20)
23 338832 Tube, Upper 1338821 (35)
24 338834 Stop, Valve 1338822 (34)
25 Seal, U-Cup, 5/8 " ID x 1 " OD 1338823 (32)
26 338831 Valve, Check 1338824-1 (31)
27 X171000-108 O-Ring, 1-7/8 " ID x 2 " OD 1338824-2 (25)
28 338830 Seat, Upper Valve 1338826 (33)
29 338829 Tube, Lower 1338827 (30)
30 Guide 1338828 (21)
31 Seal, U-Cup, 1-3/8 " ID x 1-7/8 " OD 1338829 (29)
32 Ring, Support 1338830 (28)
33 Seat, Lower Valve 1338831 (26)
34 338822 Spacer 1338832 (23)
35 338821 Plate, Valve 1338834 (24)
36 171130 Nut, Elastic Stop, 1/2 " -20 1338838 (19)
Legend:
Part numbers left blank (or in italics) are not available separately
Part numbers with an X prefix indicate a quantity of ten (10)
designates a repair kit item

Revision (6-03) 6 Alemite Corporation
SER 7735 Medium-Pressure Bulk Grease Pump
Accessories
Preventive Maintenance
Refer to section entitled Overhaul for the procedures necessary to perform maintenance.
Performance Curves
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 pounds (kilograms) per minute (X axis) to air consumption in cubic feet (liters) per minute
(right Y axis) and to material discharge pressure in psi/Bars (left Y axis).
Part Number Description
324170 Muffler
Table 2 Model 7735 Accessories
Daily Weekly Monthly Yearly
Wipe Exterior with Clean Cloth Inspect for Air and/or Material Leakage
Table 3 Model 7735 Preventive Maintenance Schedule
Figure 3 Delivery versus Discharge Pressure and Air Consumption

Medium-Pressure Bulk Grease Pump SER 7735
Alemite Corporation 7 Revision (6-03)

6-03SER 7735 Medium-Pressure Bulk Grease Pump
Revision (6-03) 8 Alemite Corporation
Overhaul
NOTE: Refer to Figure 2-A and 2-B for
component identification on all overhaul
procedures.
Prior to performing any maintenance procedure, the
following safety precautions must be observed. Personal
injury may occur.
WARNING
Do not use halogenated hydrocarbon sol-
vents such as methylene chloride or 1,1,1-trichlor-
ethane in this pump. An explosion can result
within an enclosed device capable of containing
pressure when aluminum and/or zinc-plated parts
come in contact with halogenated hydrocarbon
solvents.
Release all pressure within the system prior to
performing any overhaul procedure.
• Disconnect the air supply line from the pump
motor.
• Into an appropriate container, operate the
control valve to discharge remaining pressure
within the system.
Never point a control valve at any portion of your
body or another person. Accidental discharge of
pressure and/or material can result in injury.
Read each step of the instructions carefully. Make
sure a proper understanding is achieved before
proceeding.
Disassembly
Separate Pump Tube from Air Motor
1. Clamp the motor housing horizontally in a vise.
2. Remove Nuts (6), Lockwashers (5), and Screws (4)
that secure Camlock Adapter (19) to Air Motor
Assembly (1).
• Remove the Camlock Adapter from the Air Motor
Assembly.
3. Remove O-Ring (18) from the Camlock Adapter.
4. Unscrew Upper Tube (23) from Body (10).
• Use a strap wrench.
5. Slide the Upper Tube away from the Air Motor to
expose Lower Rod (21).
CAUTION
Support the Lower Rod assembly and piston rod
during Roll Pin (20) removal. Damage to compo-
nents can occur.
6. Remove Roll Pin (20) that secures the Lower Rod to
the piston rod.
• Use a punch and a small hammer.
7. Place a socket wrench on Nut (36) and unscrew the
Lower Rod assembly from the piston rod.
Pump Tube Upper Packing
8. Unscrew Outlet Extension (7) from Body (10).
9. Unscrew Cap Screws (17) that secure Body (10) to the
Air Motor.
• Do not remove the Cap Screws from the Body.
10. Remove the Body from the Air Motor.
• Use the Cap Screws as levers.
11. Remove O-Rings (16) from the Body.
12. Position the Body on the bench with the larger
diameter facing upward.
CAUTION
Use internal circlip pliers to remove Circlip (15).
Tension on the Circlip requires the use of Truarc #
0700-09 or equivalent pliers for removal. Damage
to component may occur.
13. Remove Circlip (15) from the Body.
14. Remove Washer (14), U-Cup Seal (13), Bearing (12),
and Seal (11) from the Body.
15. Remove O-Ring (8) and O-Ring (9) from the Body.
Pump Tube
16. Remove the Lower Rod assembly from the bottom of
Lower Tube (29).
17. Unscrew Nut (36) from the Lower Rod.
18. Remove Valve Plate (36), Spacer (34) from the Lower
Rod.
19. Remove Lower Valve Seat (33), Support Ring (32),
and U-Cup Seal (31) from the Lower Rod.
• Remove the U-Cup Seal and the Support Ring from
the Lower Valve Seat.

Medium-Pressure Bulk Grease Pump SER 7735
Alemite Corporation 9 Revision (6-03)
Assembly
NOTE: Prior to assembly, certain compo-
nents require lubrication in clean oil. Refer
to Table 4 for details.
Pump Tube Upper Packing
NOTE: Refer to Figure 4 for section view
of the upper packing components.
1. Install O-Ring (8) (smaller of the two) and
O-Ring (9) onto Body (10).
2. Position the Body with the large diameter upward.
3. Install and seat Seal (11) [heel end first] into the Body.
4. Install and seat Bearing (12) into the Body.
5. Install and seat U-Cup Seal (13) [heel end first] into
the Body.
6. Install Washer (14) onto the U-Cup Seal.
7. Install and seat Circlip (15) into the groove of the
Body.
8. Lubricate the air motor piston rod with grease.
9. Install O-Rings (16) into the top of the Body.
• Apply a dab of grease to prevent movement.
10. Install the Body assembly onto the piston rod.
• Use a small hammer or other suitable tool.
11. Rotate the Body to align the product outlet with the
hole in the base of the air motor.
12. Apply Teflon tape to Outlet Extension (7).
13. Install the Outlet Extension into the Body.
• Do not tighten at this time.
14. Install Cap Screws (17) that secure the Body to the air
motor.
• Tighten each Cap Screw securely.
15. Tighten the Outlet Extension into the Body.
20. Remove Guide (30) from the Lower Rod.
21. Unscrew Upper Tube (23) from Lower Tube (29).
22. Remove O-Ring (22) from the Upper Tube.
23. Remove Valve Stop (24) from the Lower Tube.
24. Remove Check Valve (26) with U-Cup Seal (25) from
the Lower Tube.
• Remove the U-Cup Seal from the Check Valve.
25. Remove Upper Valve Seat (28) and O-Ring (27) from
the Lower Tube.
Clean and Inspect
NOTE: Use the appropriate repair kit for
replacement parts. Make sure all the compo-
nents are included in the kit before discard-
ing used parts.
1. Clean all metal parts in a modified petroleum-based
solvent. The solvent should be environmentally safe.
2. Inspect all parts for wear and/or damage.
• Replace as necessary.
EXAMPLE: Inspect O-Ring (18) for any
nicks or cracks. Replace as necessary to
ensure an air-tight seal with Body (10).
3. Inspect Lower Rod (21) closely. Use a magnifying
glass to detect any score marks.
• Replace as necessary.
4. Closely inspect the mating surfaces of both check valve
components for any imperfections Ensure a smooth
and clean contact is obtained when assembled.
5. Inspect the lower portion of Guide (30) for grooves.
• Replace as necessary.
6. Inspect Valve Stop (24) for signs of breakage.
• Ensure the Valve Stop seats properly in the
counterbore of Upper Tube (23).
Item No.
on Figure 2-A Description Item No. on Figure 2-B Description
8O-Ring, 1-13/16" ID x 2 " OD 22 O-Ring, 2" ID x 2-1/8 " OD
9O-Ring, 1-15/16" ID x 2-1/8 " OD 25 Seal, U-Cup, 5/8 " ID x 1 " OD
11 Seal, 1-7/16 " ID x 1-13/16 " OD 27 O-Ring, 1-7/8 " ID x 2 " OD
13 Seal, U-Cup, 1-7/16 " ID x 1-15/16 " OD 31 Seal, U-Cup, 1-3/8 " ID x 1-7/8 " OD
16 O-Ring, 1/2" ID x 5/8 " OD
Table 4 Components Lubricated in Clean Oil

6-03SER 7735 Medium-Pressure Bulk Grease Pump
Revision (6-03) 10 Alemite Corporation
Pump Tube
16. Position Lower Valve Seat (33) [large diameter
downward] on the bench.
17. Install and seat Support Ring (32) onto the Lower
Valve Seat.
18. Install and seat U-Cup Seal (31) [heel first] onto the
Lower Valve Seat.
19. Position Lower Rod (21) on the bench with the roll
pin hole downward.
20. Install Guide (30) [flat side first] onto the Lower
Rod.
21. Install the Lower Valve Seat assembly [lips first]
onto the Lower Rod.
22. Install Spacer (34) and Valve Plate (35) [flat side
first] onto the Lower Rod.
23. Install Nut (36) that secures the assembly to the
Lower Rod.
• Do not overtighten.
24. Position the Lower Rod assembly vertically with the
Nut on the bench.
25. Install Lower Tube (29) [flared end first] onto the
Lower Rod assembly.
• Use care passing the U-Cup Seal.
26. Install and seat O-Ring (27) onto Upper Valve
Seat (28).
27. Install and seat the Upper Valve Seat assembly
[O-Ring upward] into the Lower Tube.
28. Install U-Cup Seal (25) [heel first] into Check
Valve (26).
29. Install and seat the Check Valve assembly [Seal
upward] onto the Lower Rod.
30. Install Valve Stop (24) onto the Lower Rod.
31. Screw Upper Tube (23) [short counter bore down]
into the Lower Tube.
• Do not tighten at this time.
32. Install O-Ring (22) onto the Upper Tube.
Attach Pump Tube to Air Motor
33. Push the Lower Rod assembly upward until the roll
pin hole is exposed above the Upper Tube. Figure 4 Pump Tube and Upper Packing Assembly
Section View
Refer to Figures 2-A and 2-B
Parts List for Parts Identification

Medium-Pressure Bulk Grease Pump SER 7735
Alemite Corporation 11 Revision (6-03)
34. Screw the Lower Rod assembly into the piston rod
until the roll pin holes align.
• Use a socket wrench.
CAUTION
Support the Lower Rod assembly and Piston Rod
during Roll Pin (20) installation. Damage to compo-
nents can occur.
35. Install Roll Pin (20).
• Use a small hammer.
36. Screw the Upper Tube into Body (10).
• Use care passing the O-Ring.
37. Tighten the Lower Tube into the Upper Tube and at the
same time the Upper Tube into the Body.
38. Install O-Ring (18) into Camlock Adapter (19).
IMPORTANT: Lightly coat the inside diame-
ter of the O-Ring with grease.
39. Install the Camlock Adapter onto Air Motor
Assembly (1).
• Use care when the O-Ring passes Body (10).
40. Install Screws (4), Lockwashers (5), and Nuts (6) that
secure the Camlock Adapter to the Air Motor
Assembly.
• Tighten the Screws securely in a crisscross pattern.
Bench Test
1. Make sure air pressure at the regulator reads zero.
2. Install air Connector (2) to the inlet of the air motor.
3. Connect Air Coupler (3) to the Connector.
4. Slowly supply air pressure [not to exceed 20 psi
(1.4 Bars] to the pump’s motor.
• The pump assembly should cycle.
If the pump assembly does not cycle, refer to the
Troubleshooting Chart for details.
With air pressure at zero:
5. Connect a product hose to the pump’s material outlet.
• Direct the hose into an appropriate collection
container.
6. Place the pump in oil.
7. Slowly supply air pressure to the pump’s motor.
8. Allow the pump to cycle slowly until the system and
oil 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:
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 oil is
once again free of air.
13. Shut off the control valve.
• Visually inspect the pump for external leaks.
• The pump should not cycle. *
If the pump does not adequately stall, refer to the
Troubleshooting Chart for details.
14. Check the motor for air leakage.
If the motor leaks, refer to the Air Motor Service
Guide for details.
* A pump that does not completely stall with oil does
not necessarily mean that it will not stall with grease.

6-03SER 7735 Medium-Pressure Bulk Grease Pump
Revision (6-03) 12 Alemite Corporation
Figure 5 Medium-Pressure Grease Pump Model 7735 (Shown with Accessories) - Typical Installation
Installation
These pumps connect to a female camlock which is
part of a bulk container system. See Figure 5 for a typical
installation.
Additional items that should be incorporated into the
air piping systems are listed in Table 5.
* Although the air motor is lubricated at the factory,
the life of the motor can be extended with the use of a
lubricator.
Part Number Description
5612-2 Moisture Separator
SM7612-B Regulator and Gauge
5912-2 Lubricator *
Table 5 Air Line Components
Prove the Pump
Aerated product is due to external leakage; either at the
pump or at the connection fittings on the bulk container.
Isolation of the pump from the bulk container can help
“prove the pump”.
1. Place the pump in oil.
2. Follow procedures 9 through 13 within the section
entitled Bench Test.
If the pump does not leak externally * the fittings on
the bulk container may not be sealing properly.
* The pump may still contain an air leak at
O-Rings (16) and/or (18). Refer to the Troubleshooting
Chart for details.

Medium-Pressure Bulk Grease Pump SER 7735
Alemite Corporation 13 Revision (6-03)
Troubleshooting Chart
Pump Indications Possible Problems Solution
Pump does not cycle 1. Insufficient air pressure
2. Air motor not operating properly
3. Pump tube jammed and/or contains loose
components
1. Increase air pressure
2. Inspect air motor and rebuild or replace as
necessary
3. Rebuild pump tube
Pump will not prime 1. Pump leaking internally
2. Improper seal between Camlock
Adapter (19) and camlock
3. Bulk container connection fittings leaking
4. Pump leaking externally
1. See Internal Leaks
2. Replace seal in camlock
3. Seal fittings and tighten securely
4. See External Leaks
Product is aerated * 1. Improper seal between Camlock
Adapter (19) and camlock
2. Bulk container connection fittings leaking
3. Pump leaking externally
1. Replace seal in camlock
2. Seal fittings and tighten securely
3. See External Leaks
Pump cycles rapidly Product source empty Replenish product
Pump will not stall (cycles more than
once or twice/hour) 1. Pump leaking internally 2. Pump leaking externally
3. Distribution system leaking
1. See Internal Leaks
2. See External Leaks
3. Correct leak
External Leaks
Product leakage from weep hole in
Body (10)
Visible at air motor base
1. Damaged U-Cup Seal (13)
2. Damaged air motor piston rod.
1. Separate pump tube from air motor and replace
U-Cup Seal (13)
2. Inspect piston rod and replace as necessary
Product leakage at bottom of Body (10)
Visible on Upper Tube (23)1. Pump tube not sufficiently tight 2. Damaged O-Ring (22)1. Tighten pump tube assembly 2. Separate pump tube from air motor and replace
O-Ring (22)
Air leakage from weep hole in
Body (10)
Felt at air motor base
Damaged Seal (11) Separate pump tube from air motor and replace
Seal (11)
Product leakage visible between Upper
Tube (23) and Lower Tube (29)1. Pump tube not sufficiently tight 2. Damaged O-Ring (27)1. Tighten pump tube assembly 2. Separate Upper Tube (23) from Lower Tube (29)
and replace O-Ring (27)
Pump will not prime or product is
aerated * 1. Damaged O-Ring (18)
2. Damaged O-Rings (16)
1. Remove Camlock Adapter (19) and replace
O-Ring (18)
2. Replace O-Rings (16)
Internal Leaks
Pump will not prime or pump will not
stall (cycles more than once or
twice/hour)
1. Foreign material between Check Valve (26) and
Upper Valve Seat (28)
2. Foreign material between Lower Valve Seat (33)
and Valve Plate (35)
3. Worn or damaged Check Valve (26)
4. Worn or damaged Upper Valve Seat (28)
5. Worn or damaged Lower Valve Seat (33)
6. Worn or damaged Valve Plate (35)
7. Worn or damaged U-Cup Seal (25)
8. Worn or damaged Lower Rod (21)
9. Worn or damaged U-Cup Seal (31)
10. Worn or damaged Lower Tube (29)
Locate and eliminate source of foreign material.
Disassemble pump tube, clean, inspect and replace
worn or damaged components.
* Should the pump aerate product, see Section entitled Prove the Pump for details.
Changes Since Last Printing
Removed Kit 393673

SER 7735 Medium-Pressure Bulk Grease Pump
Revision (6-03) 14 Alemite Corporation