Alemite 7835-SDTR1 User manual

Service Guide 7835-SDTR1
Alemite Corporation
PO Box 473515, Charlotte, North Carolina 28247-3515
www.alemite.com
Copyright © 2000 by Alemite Corporation
This document contains confidential information that is the property of Alemite Corporation
670653 and is not to be copied, used, or disclosed to others without express written permission.
Figure 1 Pump Model 7835-SDTR1
Description
NOTE: The components within the fluid-wetted path of
this pump are stainless steel and Teflon.
CAUTION
This pump is tested in mineral oil. Flush the pump thor-
oughly with a solvent compatible with the product dis-
pensed as required.
The major components of pump model 7835-SDTR1 consist of a
reciprocating air motor and a double-acting pump tube. The pump
tube is divorced from the motor which:
• protects the motor from product contamination
• allows separation without product leakage
The pump tube is designed to enable the delivery of a variety of
materials. This medium-pressure (5:1) pump includes a bung adapter
[2 " NPTF (m)] that allows operation directly from original 55-gallon
(200/205 l) drums
Specifications
Air Motor
Pump Tube
Piston
Diameter x Stroke Air Inlet
Maximum
Air Pressure
In Cm psi Bars
3 x 1-5/8 7.6 x 4.1 1/4 " NPSI (f) 200 13.8
For details on the air motor, refer to Service Guide SER 338905
See Figure 2 for performance curves.
Material
Outlet
Max.
Material
Pressure Max. Free-Flow
Delivery/Minute * Recommended
Continuous
Delivery/Minute Displacement
per Cycle
psi Bars Gallons Liters Gallons Liters In 3Cm 3
3/4 " NPTF (f) 1000 69 4.5 17 2.75 10.4 3.6 59
See Figure 2for performance curves.
* SAE 10 oil at 75 ° F (24 ° C) and 100 psi [6.9 Bars] air pressure.
Table 1 Pump Model 7835-SDTR1 Specifications
Medium-Pressure Stainless Pump
SER 7835-SDTR1
Revision 8-00
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SER 7835-SDTR1 Medium-Pressure Stainless Pump
Figure 2 Delivery versus Discharge Pressure and Air Consumption
Accessories
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 four different air pressures.
The curves relate delivery in gallons (liters) 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).
Air Hose Cover
55-Gallon 200/205 Liter
317803-7 318040-4 338984
322590-4 *
* This cover contains an inspection/fill port
Table 2 Pump Model 7835-SDTR1 Accessories
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Medium-Pressure Stainless Pump SER 7835-SDTR1
Alemite Corporation 3 Revision 8-00
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
1 Motor Assembly, Air 1See SER 338905 171604 (8)
2 328034 Adapter, 1/4 ’’NPTF (m) 1321639 (4)
3 328030 Coupler, 1/4 ’’NPTF (f) 1328030 (3)
4 321639 Cover 1328034 (2)
5 Tube Assembly, Pump 1See Figure 3-B 330050 (6)
6Bar,Adjustment 1338904 (5)
7 Washer, Flat, 1/4 ’’ 3338905 (1)
8 Screw, 1/4 ’’-20 x 7/8 ’’ 3380667 (7)
Legend:
Part numbers left blank (or in italics) are not available separately
Figure 3-A Medium-Pressure Stainless Pump Model 7835-SDTR1 - Exploded View
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SER 7835-SDTR1 Medium-Pressure Stainless Pump
Revision 8-00 4 Alemite Corporation
Figure 3-B Medium-Pressure Stainless Pump Model 7835-SDTR1 - Exploded View
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Medium-Pressure Stainless Pump SER 7835-SDTR1
Alemite Corporation 5 Revision 8-00
Item
No. Part No. Description Qty Notes Numeric Order
Part # (Item #)
9322321 Nut, Packing (Stainless Steel) 1171120 (14)
10 322323 Ring, Female Adapter (Stainless Steel) 1171701-80 (34)
11 326069-24 Ring, Packing, 1-1/4 ’’ID x 1-3/4 ’’OD (Teflon) 8317419 (33)
12 322325 Ring, Male Adapter (Stainless Steel) 1317426 (22)
13 322324 Body, Outlet (Stainless Steel) 1317428 (29)
14 Plug, Pipe, 3/8 ’’NPT (m) (Stainless Steel) 1318809 (19)
15 322322 Rod, Packing (Stainless Steel) 1318853 (21)
16 319179 Coupling (Stainless Steel) 1318854 (23)
17 318859 Pin, Cotter, 1/8 ’’x 1-1/4 ’’(Stainless Steel) 2318855 (35)
18 322329 Rod (Stainless Steel) 1318859 (17)
19 318809 Nut, 5/8 ’’-18 (Stainless Steel) 1318862 (26)
20 319188 Stop (Stainless Steel) 1319179 (16)
21 318853 Spacer (Stainless Steel) 1319188 (20)
22 317426 Spacer (Stainless Steel) 1319334 (27)
23 318854 Adapter (Stainless Steel) 1322321 (9)
24 331745 Washer, Lipped 1.19 ’’(Stainless Steel) 1322322 (15)
25 323126 Cup, 1.187 ’’ID x 1.805 ’’OD (Teflon) 2322323 (10)
26 318862 Spacer (Stainless Steel) 1322324 (13)
27 319334 Washer, 1.19 ’’(Stainless Steel) 1322325 (12)
28 327664 Body, Valve (Stainless Steel) 1322326 (30)
29 317428 Seat, Valve (Stainless Steel) 1322329 (18)
30 322326 Gasket (Stainless Steel) 3323126 (25)
31 326908-2 Cylinder (Stainless Steel) 1326069-24 (11)
32 326750-A1 Adapter, Bung, 2 " NPTF (m) (Stainless Steel) 1326750-A1 (32)
33 317419 Washer, Stop (Stainless Steel) 1326908-2 (31)
34 171701-80 Ball, 1-1/4 ’’Dia. (Stainless Steel) 1327664 (28)
35 318855 Body, Foot Valve (Stainless Steel) 1331745 (24)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
Repair Kits
Part No. Kit Symbol Description
393660 Kit, Major Repair
323590-3 Kit, Minor Repair
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SER 7835-SDTR1 Medium-Pressure Stainless Pump
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Medium-Pressure Stainless Pump SER 7835-SDTR1
Alemite Corporation 7 Revision 8-00
Pump Tube Assembly
Outlet Body Assembly
5. Unscrew Packing Nut (9) from the Outlet Body.
•UseAdjustmentBar(6).
6. Unscrew the Outlet Body from Cylinder (31).
7. Remove Gasket (30) from the bottom of the Outlet
Body.
8. Remove Female Adapter Ring (10), Packing Rings
(11), and Male Adapter Ring (12) from the Outlet
Body.
9. Unscrew Pipe Plug (14) from the Outlet Body as
required.
Foot Valve Body Assembly
10. Unscrew Foot Valve Body (35) from the Cylinder.
11. Remove Gasket (30), Stop Washer (33), additional
Gasket (30), and Ball (34) from the Foot Valve Body.
Packing Rod Assembly
12. Remove Packing Rod (15) [with attached components]
from the bottom of the Cylinder.
13. Unscrew Valve Seat (29) from Rod (18).
14. Remove Adapter (23) [with attachments] and Spacers
(21) and (22) from the Rod.
15. Unscrew Stop (20) and Nut (19) from the Rod as
required.
Adapter Assembly
16. Unscrew Valve Body (28) from the Adapter.
17. Remove Washer (27), Cup (25), Spacer (26),
Additional Cup (25), and Washer (24) from the
Adapter.
Rod Assembly
18. Remove Cotter Pins (17) that secure Rod (18) and
Packing Rod (15) from Coupling (16) as required.
19. Unscrew each Rod from the Coupling.
Bung Adapter
20. Remove Bung Adapter (32) from the Cylinder as
required.
Overhaul
NOTE: Refer to Figures 3-A and 3-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
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. Material discharged at
high velocity can penetrate the skin and cause
severe injury. Should any material appear to punc-
ture the skin, get medical care immediately.
Read each step of the instructions carefully. Make
sure a proper understanding is achieved before
proceeding.
Disassembly
Separate Air Motor from Pump Tube
1. Clamp the Pump Assembly vertically in a soft-jaw vise
at Bung Adapter (32).
2. Remove Cover (4) from Outlet Body (13).
3. Remove Screws (8) and Washers (7) that secure Air
Motor Assembly (1) to the Outlet Body.
4. Pull the Air Motor Assembly until its connection with
Packing Rod (15) is above the Outlet Body.
• Slide the Air Motor Assembly from the Packing
Rod.
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SER 7835-SDTR1 Medium-Pressure Stainless Pump
Clean and Inspect
1. Clean all metal parts in cleaning solvent. The solvent
should be environmentally safe.
2. Inspect all parts for wear and/or damage.
• Replace as necessary.
3. Inspect Packing Rings (11) and Cups (25) for wear.
• Replace as necessary.
4. Inspect Packing Rod (15) and lower bore of Cylinder
(31) for any score marks.
• Replace as necessary.
5. Closely inspect the mating surfaces of all check valve
components for any imperfections. Ensure a smooth
and clean contact is obtained when assembled.
EXAMPLE: Place Ball (34) into Foot Valve
Body (35). Fill the Foot Valve Body with
solvent. Make sure no leakage occurs.
Assembly
NOTE: Prior to assembly, certain compo-
nents require lubrication in clean mineral
oil. Refer to Table 3 for details.
Pump Tube Assembly
Outlet Body
1. Clamp Outlet Body (13) [cage end upward] into a soft-
jaw vise.
1. Screw Pipe Plug (14) [with thread sealant] into the
Outlet Body.
• Tighten the Plug securely.
2. Install and seat Male Adapter Ring (12) [flat side
first], Packing Rings (11) [lip side first], and Female
Adapter Ring (10) [flat side upward] into the top of the
Outlet Body.
3. Screw Packing Nut (9) into the Outlet Body loosely.
IMPORTANT: The Packing Nut will require
adjustment. Refer to the section entitled
Bench Test and Operation for details.
Item No. Description
15 Packing Rod
31 bore of Cylinder
Table 3 Components Lubricated in Clean Mineral Oil
4. Install Packing Rod (15) [threaded end first] into the
top of the Outlet Body.
• Allow the threaded end to extend from the bottom of
the Outlet Body.
5. Screw Coupling (16) onto the Packing Rod until the
cotter pin holes align.
6. Install Cotter Pin (17).
Adapter
7. Position Adapter (23) small diameter upward.
8. Install and seat Washer (24) [lip upward], Cup (25) [lip
first], Spacer (26) [large diameter first], additional Cup
(25) [lip first], and Washer (27) onto the Adapter.
9. Screw Valve Body (28) onto the Adapter.
• Tighten the Valve Body until it bottoms.
Rod
10. Screw Nut (19) to the top of Rod (18).
11. Screw Stop (20) onto the Rod until it bottoms.
12. Tighten Nut (19) to the Stop.
13. Install Spacers (21) and (22) onto the Rod.
14. Install the Adapter assembly [Adapter end fist] onto
the Rod.
15. Screw Valve Seat (29) onto the Rod until it bottoms.
16. Measure the distance from the bottom of Stop (20) to
the top of Spacer (21).
• The distance must not be less than 0.20 " (5.1 mm)
and no greater than 0.28 " (7.1 mm). See Figure 4.
NOTE: This setting effects the efficiency of
the pump.
Cylinder
17. Install Cylinder (31) [bottom end first] onto the top of
the Rod and Adapter assembly.
• Allow the Rod to extend from the top of the Cylinder.
18. Position the Outlet Body horizontally in the vise.
19. Install and seat Gasket (30) into the bottom of the
Outlet Body.
20. Screw the Rod of the Cylinder assembly into the
Coupling until the cotter pins holes align.
21. Install Cotter Pin (17).
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Medium-Pressure Stainless Pump SER 7835-SDTR1
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22. Screw the Cylinder assembly [with Loctite
242] into the Outlet Body.
• Do not tighten at this time.
23. Install Bung Adapter (32) onto the Cylinder.
Foot Valve Body
24. Install Ball (34) Gasket (30), Stop Washer
(33) [flat side first], and additional Gasket
(30) into Foot Valve Body (35).
25. Screw the Foot Valve Body assembly onto
the Cylinder.
26. Tighten the Foot Valve Body into the
Cylinder and at the same time the Cylinder
into the Outlet Body.
• Position a bar or similar tool in the groove
of the Foot Valve Body
• Make sure to properly crush the Gaskets.
Connect Air Motor to Pump Tube
27. Position the Outlet Body vertically in the
vise.
28. Pull Packing Rod (15) above the Outlet
Body.
29. Slide the Air Motor Assembly onto the
Packing Rod.
30. Push Air Motor Assembly (1) downward
against the Outlet Body.
31. Install Screws (8) and Washers (7) that
secure the Air Motor Assembly to the
Outlet Body.
• Tighten the Screws securely.
Bench Test and Operation
WARNING
Do not exceed the lowest pres-
sure rating of any component in the sys-
tem.
Ensure all components are in operable
condition. Replace any suspect parts
prior to operation.
Should leakage occur anywhere within
the system, disconnect air to the motor.
Personal injury can occur.
Figure 4 Pump Tube Assembly 338904 - Section View
Refer to Figure 3-B Parts List
for Parts Identification
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SER 7835-SDTR1 Medium-Pressure Stainless Pump
Revision 8-00 10 Alemite Corporation
Initial Prime
1. Place the pump in the material to be dispensed.
2. Connect a product hose to the pump’s material outlet.
• Direct the hose into an appropriate collection
container.
3. Screw Connector (2) [with thread sealant] into the inlet
of the Air Motor Assembly.
• Tighten the Connector securely.
4. Install Air Coupler (3) onto the air supply line.
5. Make sure air pressure at the regulator reads zero.
6. Connect the Air Coupler assembly to the Connector.
7. Slowly supply air pressure to the pump’s motor.
8. Allow the pump to cycle slowly until the material is
free of air.
If the pump assembly does not prime, refer to the
Troubleshooting Chart for details.
Starting Pressure
9. Set the air pressure to 20 psi (1.4 Bars).
10. Insert Adjustment Bar (6) into a hole of the Packing
Nut.
11. Adjust the Packing Nut until the pump assembly stops.
12. Loosen the Packing Nut until the pump assembly
begins to cycle.
Leakage and Stall
WARNING
Should leakage occur anywhere within the
system, disconnect air to the motor. Personal
injury can occur.
With air pressure at zero:
13. Attach a control valve to the outlet hose of the pump.
• Make sure the nozzle on the control valve is open.
14. Slowly supply air pressure to the pump’s motor.
15. Allow the pump to cycle slowly until the material is
once again free of air.
16. Set the air pressure to the normal operating pressure.
17. Operate the control valve into a container.
18. Shut off the control valve.
• Visually inspect the pump for external leaks.
• The pump should not cycle more than once or twice
in one hour.
If the pump leaks or does not stall, refer to the
Troubleshooting Chart for details.
19. Install Cover (4) onto the Outlet Body.
20. Check the motor for air leakage.
If the motor leaks, refer to the Air Motor Service
Guide for details.
Installation
Additional items that should be incorporated into the
air piping systems are listed in Table 4.
Packing Ring Adjustment
IMPORTANT: Break-in and wear of upper
packing rings require the user to readjust the
Packing Nut:
• after approximately 6 hours of initial operation *
• anytime the upper packing rings leak
1. Make sure the air pressure is zero.
2. Operate the control valve into a container.
• This releases any pressure within the system.
3. Remove Cover (4) from the Outlet Body as required.
4. Insert the Adjustment Bar into a hole of the Packing
Nut.
5. Tighten Packing Nut (9) clockwise 1/4-turn.
6. Set the air pressure to 20 psi (1.4 Bars).
7. Hold the control valve open while aiming into a
suitable collection container.
8. Loosen the Packing Nut until the pump assembly
begins to cycle.
9. Install Cover (4) onto the Outlet Body.
* Applies to new and overhauled pumps.
Part Number Description
5604-2 Moisture Separator
7604-B Regulator and Gauge
Table 4 Air Line Components
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Medium-Pressure Stainless Pump SER 7835-SDTR1
Alemite Corporation 11 Revision 8-00
Troubleshooting Chart
Pump Indications Possible Problems Solution
Pump does not cycle 1. Packing Rings (11) too tight
2. Air motor not operating properly
3. Pump tube jammed and/or contains
loose components
4. Insufficient air pressure
1. Adjust Packing Nut (9)
2. Inspect air motor and rebuild or replace
as necessary
3. Rebuild pump tube
4. Increase air pressure
Pump will not prime 1. Excessive cycling speed
2. Pump leaking internally 1. Reduce air pressure 2. See Internal Leaks
Pump cycles rapidly Product source empty Replenish product
Pump will not stall (cycles
more than once or
twice/hour)
1. Pump requires break-in period
2. Pump leaking internally
3. Pump leaking externally
4. Distribution system leaking
1. Operate the pump against moderate
material pressure for up to one hour
2. See Internal Leaks
3. See External Leaks
4. Correct leak
External Leaks
Product leakage visible at
torque hole in Packing Nut (9)1. Packing Nut (9) not sufficiently tight
2. Worn or damaged Packing Rings (11)
3. Damaged Packing Rod (15)
1. Tighten Packing Nut (9) with use of
torque bar
2. Replace Packing Rings (11)
3. Inspect Packing Rod (15) and replace as
necessary
Product leakage visible at
bottom of Outlet Body (13)1. Damaged Gasket (30) 2. Cylinder (31) not sufficiently tight 1. Replace Gasket (30) 2. Tighten Cylinder (31) into Outlet Body
(13)
Product leakage between
Cylinder (31) and Foot Valve
Body (35)
1. Worn or damaged Gaskets (30)
2. Foot Valve Body (35) not sufficiently
tight
1. Replace Gaskets (30)
2. Tighten Foot Valve Body (35) into
Cylinder (31)
Internal Leaks
Pump does not prime or cycles
continuously, or
slowly (once or twice/hour)
1. Foreign material between Ball (34) and
Foot Valve Body (35)
2. Foreign material between Valve Body
(28) and Valve Seat (29)
3. Worn or damaged Ball (34)
4. Worn or damaged Foot Valve Body (35)
5. Worn or damaged Valve Body (28)
6. Worn or damaged Valve Seat (29)
7. Worn or damaged Cup (25)
8. Worn or damaged Cylinder (31)
Locate and eliminate source of foreign
material
Disassemble pump tube, clean, inspect,
and replace worn or damaged components
Changes Since Last Printing
Changed Cylinder 326908-2
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SER 7835-SDTR1 Medium-Pressure Stainless Pump
Revision 8-00 12 Alemite Corporation
Every effort has been made to ensure that the information within this publication is accurate.
Please send any comments or inquiries to chris.schrad[email protected]
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