Alemite 7783 Series Operating instructions

SER 7783-A4
SERVICE INSTRUCTIONS
7783-A4 , 7783-B4 and 7783-C4
Low Pressure Fluid Lubricant Pumps
7783-A4
7783-B4
7783-C4
DESCRIPTION
Model 7783 Series Pumps are single-action, low pressure units de-
signed to deliver fluid lubricants from original containers or bulk
tanks.
The differences in the pumps are that model 7783-A4 is used with
55-gallon drums , model 7783-B4 is used with 16-gallon drums and
model 7783-C4 is a stub pump and can be used with extensions .
All models produce a 6:1 material-to-air pressure ratio. The maximum
operating air pressure of 200 psi would,therefore, create a maximum
material pressure of 1200 psi.
The pumps are capable of supplying a high volume of lubricant at a
low rate of speed (e.g.-At 100 psi air pressure,the pump delivers 10
gallons of SAE No. 140 gear oil per minute).
NOTE: The air motor (323440-4) is packed with lubricant at the fac-
tory and should require no additional lubrication.
SPECIFICATIONS
PUMP:
Ratio ..............................................................................................:6:1
Recommended Operating Air Pressure ..............................50-175 psi
Maximum Operating Air Pressure ........................................... 200 psi
Maximum Operating Material Pressure .................................1200 psi
Displacement ..............................................................9.8 cu. in./cycle
Weight (basic pump, approx.) ................................................... 50 lbs.
Dimensions (Figure 1):
“A” (Model7783-A4) ...................................................... 51-23/32”
(Model 7783-B4).........................................................44-7/32”
(Model Tl83-C 4) ..........................................................32-1/8”
“B” (Model 7783-A4) ................................................................33”
(Model7783-B4) ......................................................... 25- 1/2”
(Model 7783-C4) ...................................................... 13-13/22”
Figure 1: Series 7783 Low-Pressure Pump
AIR MOTOR:
Air Inlet ........................................ ....................................3/4” NPTF
Air Outlet ...........................................................................1 /4” NPTF
Material Outlet ....................................................................1/2” NPTF
Piston Diameter ......................................................................... 4-1/4”
Stroke................................................................................................4”
GENERAL SAFETY REQUIREMENTS
Because these units are incorporated into pressure pumping systems,
it is good practice to observe and use the following safety precautions:
1 Do not exceed the pressure rating of any component in the system.
2 Protect all material and air supply lines from damage or puncture.
FOR FURTHER SERVICE, CONTACT YOUR LOCALALEMITE DISTRIBUTION CENTER
Alemite , LLC
167 Roweland Drive, Johnson City, Tennessee 37601
www .alemite.com
396686 SER 7783-A4
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SER 7783-A4
List of Accessories
Name of ltem Part No.
Cover Assembly for 120-pound Drums 323800-4
Cover Assembly for 400-pound Drums 323847-4
Bung Adapter 326750-B1
Low-Level Cut Off Switch (7783-C4 only) 321206
Extension Tube (7783-C4 only) 337123-1
Figure 2: Components of Series 7783 Low-Pressure Fluid-Lubricant Pumps
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SER 7783-A4
3 Check all hoses for weak or worn conditions prior to daily work op-
erations, making certain that all connections and fittings are secure.
4 Never point dispensing device at oneself or at any other person: ac-
cidental discharge of pressure will result in serious injury.
5 Release all pressures within the system before attempting to re-
move or service any components in the system.
6 Be sure to read all instructions and any other explanatory material
carefully and thoroughly, before attempting to assemble, disassem-
ble, or operate the system.
INSTALLATION
NOTE: Remove all shipping seals from air motor 323440-4 and
pump tube assembly.
1 Thread male adapter 328037 into 3/4” air inlet of air motor
(Figure 2).
2 Thread air coupler 328031 onto facility air hose.
3 If unit is equipped with eyebolt, remove pipe plug from top of air
motor and replace with eyebolt (Figure 2).
4 If unit is to be used with an optional cover assembly, perform the
following steps:
NOTE: It may be desirable to lift pump (by eyelet) with a hoist for
ease in installing cover assembly onto pump.
4.1 Slide cover over pump tube and align four (4) holes of cover
with holes on underside of air motor assembly.
4.2 Secure cover using four (4) stop nuts and four (4) screws
(supplied).
4.3 Install three (3) thumb screws into openings on side of cover.
5 Install and secure pump into drum, tank, or suction pipe.
6 Connect material hose (not supplied) to 1/2” material outlet of air
motor assembly.
7 Connect air coupler 328031 of facility air hose to male adapter
328037 in air motor assembly.
OPERATION
CAUTION
If dispensing devise is used with the system, never point it at
oneself or any other person. Accidental discharge of material
may result in serious injury.
1 Check entire system (fittings, hoses, connections, etc.) for leaks or
signs of wear.
IMPORTANT: Extra care should be taken to protect material lines
from damage or wear. Do not kick hose or place near sharp moving
objects. ACCIDENTAL DISCHARGE OF MATERIAL MAY RESULT
IN SERIOUS INJURY.
2 Gradually turn on air supply while checking for leaks in the system.
3 Adjust air pressure to receive desired material pressure.
NOTE: The use of an air regulator (not supplied) is recommended to
determine and control air pressure.
CAUTION
Maximum operational air pressure is 200 psi. DO NOT exceed
this limit.
4 If no leaks are present and system stalls out, pump is now ready for
use.
CAUTION
DO NOT operate unit if condition of any parts are in question.
MAINTENANCE
Do the following periodically:
1 Check for any damage to material or air supply lines.
2 Check all connections and fittings for tightness.
3 Check level of material in drum.
NOTE: Do not allow pump to run “dry” at any time.
Noise level test
Distance 60 psi (4,1 bar) 100 psi (6,8bar)
3 ft. (0,9 m)95 dB 95 dB
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SER 7783-A4
SERVICE
CAUTION
Before beginning service or attempting to disassemble any part
of unit, shut off air supply, reduce material pressure to zero, dis-
connect air and material supply lines, and remove entire pump
from container or system.
IMPORTANT: Prior to reassembly, lubricate all “O” rings, seals and
packings with SAE No. 1O oil or light machine oil. Protect all seals
and sealing surfaces from damage and scratches in any way possible.
DISASSEMBLY
A. SEPARATING PUMP TUBE FROM AIR MOTOR: (Figure 2)
1 Loosen jam nut 333256 securing pump tube to air motor assembly
323440-4.
2 Unthread pump tube assembly from air motor assembly and pull to
expose coupling 323439.
3 Remove upper spring clip 324648 from coupling..
4 Unthread coupling from air motor piston rod by rotating entire
pump tube .assembly.
B. SERVICING AIR MOTOR ASSEMBLY:
To service the 323440-4 Air Motor Assembly, refer to Instruction
Sheet SER 323440-4.
C. SERVICING BODY & PACKING GROUP: (Figure 3)
1 Unscrew and remove adapter 327706 from body of air motor as-
sembly 323440-4 (Figure 2).
2 Remove washer 323419 and bushing 324274 from adapter.
3 Unscrew three screws 323787 and pull body 323786 from air motor
assembly.
4 Remove ”O” rings 171009-33 and 171009-35 from body.
Figure 3: Body and Packing Group
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SER 7783-A4
Figure 4: Pump-Tube Assembly for Model 7783-C4 Figure 5: Pump-Tube Assembly for Models 7783-A4 & 7783-B4
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SER 7783-A4
5 From bottom of body, remove gasket 323693, washer 332465, sec-
ond gasket 323693 and spacer 332466.
6 Early. models: remove the bearing, four packings, the lantern ring,
two packings and block “V” packing through the bottom of body
NOTE: Early models using this old style of packings must be changed
to the urethane seal design in repair kits 393040-1 or 398986-2.
Later Models:
Remove washer 337361, seal 172190-6, lantern ring 337362, seal
172190-5, spacer 337363, and “0” ring 171009-13 through bottom of
body.
NOTE: At reassembly, lips of seals 172190-5 and 172190-6 must face
downward as shown in Figure 3A.
7 Clean and inspect all parts for wear and damage.
8 Reassemble by reversing the above steps.
D. SERVICING PUMP TUBE ASSEMBLY:(Figures 4 & 5)
1 If you have not already done so, disconnect pump tube from air mo-
tor as previously described in “SEPARATING PUMP TUBE FROM
AIR MOTOR”section of SERVICE.
2 Grab upper coupling 323439 and pull upward until contents of pump
tube is removed from cylinder 333356-1, 333356-2 (Figure 5) or
333356-3 (Figure 4).
3 Remove lower spring clip 324648 from upper coupling 323439. Un-
thread and remove upper coupling from rod 323438-2 (Figure 4),
323438-1 or 333438-5 (Figure 5).
4 Remove two spring clips 324648 from lower coupling 323439. Un-
thread and remove rod from lower coupling, then remove lower cou-
pling from adapter 323751.
5 Unthread and remove valve seat 323707 from adapter 323751. Re-
move piston 338120, ball 171700-36, and spring 336438 (Figure 4)
or 323712 (Figure 5).
NOTE: At reassembly, apply LOCTITE ® 242 ® to male threads of
valve seat 323707 prior to installation. Do not tighten more than 1/4
turn after coming in contact with piston 338120. Allow 1-2 hours to
cure.
6 Gripping foot valve body 323778 (Figure 4) or 323708 (Figure 5),
unthread cylinder from foot valve body.
7 Model 7783-C4 only.
Remove “O” ring 171009-31 from foot valve body (Figure 4).
8 Tap out pin 323713 from foot valve body and remove ball
1722703-13.
9 Clean and inspect all parts for wear or damage.
IMPORTANT: Worn or damaged parts present a threat to personnel
and property. NEVER reuse worn or damaged parts.
REASSEMBLY:
Reassemble each section by reversing steps used to disassemble and
observe the accompanying notes.
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SER 7783-A4
Major Repair Kits
* 398986-2 For Series 7783 Pump-Tube Assemblies
Part No. Figure Description Qty.
171009-13 3 “O” Ring, 1-3/16” 1.D. x 1-5/16” O.D 1
171009-31 4 “O” Ring, 1-11/16” l.D. x 1-7/8” O.D (Model 7783-C4) 1
171009-33 3 “O” Ring, 1-3/16” 1.D. x 2” 0.D. 1
171009-35 3 “O” Ring, 1-15/16” l.D. x 2-1/8” O.D 1
171700-36 4, 5 Ball, 9/16” Diameter 1
■ 172190-5 3  Seal,1-1/16”O.D.and1/4”thick   1
■ 172190-6 3  Seal,1-9/16”O.D.x3/8”thick   1
323419 3 Washer, 7/8” l.D. x 1-19/64” O.D 1
323693 3 Aluminium Gasket, 1-29/32” O.D 2
323707 4, 5 Valve Seat 1
323712 5 Heavy Spring, 15/32” dia. x 27/32” long (7783-A4 & B4) 1
324274 3 Bushing 1
324648 4, 5 Spring Clip 4
336438 4 Light Spring, 15/32” dia. x 49/64” long (Model 7783-C4) 1
337361 3 Washer, 1-35/64” 0.D 1
337362 3 Lantern Ring 1
337363 3 Spacer 1
338120 4,5 Piston 1
* This kit is used for repairing the pump-tube assemblies in 7783-A4, 7783-B4 and 7783-C4. The parts that are used for a specific
pump tube are noted in the kits list.
■Thesetwopartscanbepurchasedseparatelyinpacksoffiveforminorrepairs.Orderreplacement-sealkit393530-5(Fiveeachof
172190-5) or 393530-6 (Five each of 172190-6).
393040-1 For Body and Seal Group (Figure 3)
Part No. Description Qty.
171009-13 “O” Ring, 1-3/16” l.D. x 1-5/16” 0.D 1
171009-33 “O” Ring, 1-3/16” l.D. x 2” O.D 1
171009-35 “O” Ring, 1-15/16” l.D. x 2-1/8” O.D 1
■ 172190-5  Seal,1”1/16’’O.D.and1/4”thick  1
■ 172190-6  Seal,1-9/16”O.D.x3/8”thick  1
323419 Washer, 7/8” l.D. x 1-19/64” 0.0 1
323693 Aluminum Gasket, 1-29/32” O.D 2
337361 Washer,1-35/64” O.D 1
337362 Lantern Ring 1
337363 Spacer 1
■ SeenoteinKit398986-2.
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SER 7783-A4
PARTS LIST• 7783 Series Lubricant Pumps (Figure 2)
Part No. Description Qty.
■+ 323440-4 Air-Motor Assembly 1
323842 Eyebolt (7783-A4 and 7783-B4) 1
• 324648 Spring Clip 1
328031 Air Coupler (Female) 1
328037 Male Adapter 1
333256 Jam Nut, 2-16 UN 1
*+   Body’andPackingGroup (Figure 3) 1
*+Pump-Tube Assembly (Figure 4 or 5) 1
•Repair Kit Part
* See separate parts list.
■ SeepartslistinSER323440-4
+ Not available as a separate purchased part.
PARTS LIST• Body and Packing Group (Figure 3)
Part No. Description Qty.
10522 Pipe Plug 1
•171009-13 “O” Ring, 1-3/16” l.D. x 1-5/16” O.D. 1
• 171009-33  “O”Ring,1’13/16”l.D.x2”O.D  1
•171009-35 “O” Ring, 1-15/16” 1.0. x 2-1/8” O.D. 1
•▼ 172190-5  Seal,1-1/16”O.D.and1/4”thick  1
•▼ 172190-6  Seal,1-9/16”0.D.x3/8”thick   1
•323419 Washer, 7/8” l.D.x 1-19/64” O.D. 1
•323693 Aluminum Gasket, 1-29/32” O.D. 2
323786 Body 1
323787 Hex-Head Cap Screw, 1/2-13 (Special) 3
•324274 Bushing 1
327706 Adapter 1
332465 Steel Washer, 1-9/16” 1.0. x 1-15/16” O.D. 1
332466 Spacer 1
• 337361 Washer, 1-35/64” O.D 1
• 337362 Lantern Ring 1
•337363 Spacer 1
• Repair Kit Part
▼ Order393530-5(Packof5)
▲ Order393530-6(Packof5)
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SER 7783-A4
PARTS LIST• Pump Tube Assembly (Model 7783-C4, Figure 4)
Part No. Description Qty.
•171009-31 “O” Ring, 1-11/16” l.D. x 1-7/8” O.D 1
•171700-36 Ball, 9/16” Diameter 1
172270-13 Ball, 1-1/16” Diameter 1
323438-2 Rod 1
323439 Coupling 2
• 323707 Valve Seat 1
323713 Pin 1
323751 Adapter 1
323778 Foot-Valve Body 1
•324648 Spring Clip 3
Cylinder 1
•336438 Light Spring, 15/32” dia. x 49/64” long 1
•338120 Piston 1
•Repair Kit Part
PARTS LIST - Pump Tube Assembly (Models7783-A4 and 7783-B4, Figure 5)
Part No. Description Qty.
• 171700-36 Ball, 9/16” Diameter 1
Ball, 1,1/16” Diameter 1
▲ 323438-1  Rod     1
▼ 323438-5  Rod     1
323439 Coupling 2
•323707 Valve Seat 1
323708 Foot-Valve Body 1
•323712 Heavy Spring, 15/32” dia. x 27/32” long 1
323713 Pin 1
323751 Adapter 1
•324648 Spring Clip 3
▼ 333356-1  Cylinder     1
▲ 333356-2  Cylinder     1
•338120 Piston 1
•Repair Kit Part
▼ 7783-A4
▲ 783-B4
NOTE: The parts listed in this instruction sheet are for reference identification in the instructions and illustrations. Some of them are not avail-
able as separate parts and these are noted in the parts list. Standard items such as nuts, bolts, etc. should be purchased at a hardware store. Refer
to the current parts price list and bulletins before ordering parts, and always give the part number, quantity, description and model where used
when ordering parts. Parts availability and prices are subject to change without notice
PART CHANGES SINCE LAST PRINTING
Correct heading
Revision (3-15)Alemite LLC
Loctite and 242 are Trademarks of Henkel Corporation in the U.S. and elsewhere. ® denotes a trademark registeresd in the U.S. Patent and
and Trademark Office.
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SER 7783-A4
Declaration of conformity as defined by
Machinery Directive 2006/42/EC
This is to declare that the design of the low pressure fluid lubricant
pump complies with the provisions of directive 2006/42/CG
Applied standards:
• EN 292-1 Safety of Machinery - Basic Concepts, General Princi-
ples and Design - Part 1: Basic Terminology, Methodology
• EN 292-2 Safety of Machinery - Basic Concepts, General Princi-
ples and Design - Part 2: Technical Principles and Specifications -
Incorporates amendments 1 (1995) and 2 (1997) EN 809 Pumps
and Pump Units for Liquids - Common Safety Requirements
• EN 349 Safety of Machinery - Minimum Gaps to Avoid Crushing
of Parts of the Human Body
St. Louis, MO 08/14,
Bob Hoefler, Director Product Development and Product Engineering
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