Alemite 7880-C1 User manual

Service Guide 7880-C1
SER 7880-C1
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
396745 and is not to be copied, used, or disclosed to others without express written permission. Revision (6-00)
Figure 1 Low-Pressure Pump Model 7880-C1
Description
The major components of low-pressure pump model 7880-C1
consist of a reciprocating differential air motor and a double-acting
pump tube.
The pump is designed to deliver a mixture of antifreeze and
water. It can also be used to dispense windshield washer fluid and
water.
This low-pressure (2-1/2:1 ratio) pump includes a 2 " NPTF (m)
thread for mounting on the 2 ’’bung thread of a drum or tank. With
the use of an extension (not included) the pump can accommodate
different size drums and tanks.
The pump can also mount to a wall (with the use of a wall
bracket) and be used with an optional siphon wand kit. See Table 4
for details.
Specifications
Differential Air Motor
Pump Tube
Piston
Diameter x Stroke Effective Piston Area * Air Inlet
Maximum Air
Pressure
In Cm In2Cm2psi Bars
2-1/16 x 4 5.2 x 10.2 1.67 10.8 1/4 " NPTF (f) 200 13.8
For details on the air motor, refer to Service Guide SER 318450-4.
See Figure 3 for performance curves.
* The effective piston area of a differential air motor is equal to one-half the
actual area of the piston.
Fluid
Outlet
Max. Fluid
Pressure Max. Free-Flow Delivery/Minute * Recommended
Continuous
Delivery/Minute Displacement
per Cycle
psi Bars Gallons Liters Gallons Liters In 3Cm 3
3/8 " NPTF (f) 500 34.5 7 26.5 4-1/4 16.1 5.4 88
See Figure 3 for performance curves.
* At 100 psi (6.9 Bars) air pressure
Table 1 Low-Pressure Pump Model 7880-C1 Specifications
Low-Pressure Pump

SER 7880-C1 Low-Pressure Pump
Revision (6-00) 2 Alemite Corporation
Figure 2 Low-Pressure Pump Model 7880-C1 - Exploded View

Low-Pressure Pump SER 7880-C1
Alemite Corporation 3 Revision (6-00)
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
1 Motor Assembly, Air 1 See SER 318450-4 (1)
2 328034 Connector, 1/4 " NPTF (m) 1 X171003-3 (10)
3 328030 Coupler, Air, 1/4 " NPTF (f) 1 171701-32 (16)
4Clip 1 171701-56 (21)
5 324484 Rod, Piston (Stainless Steel) 1 303292 (18)
6 336442 Screw, Packing 1 322164 (15)
7 Ring, Back-Up, Female (Brass) 1 323127 (13)
8 326069-18 Ring, Packing (Glass-Filled Teflon) 4 323596 (14)
9 Ring, Support, Male (Brass) 1 324484 (5)
10 X171003-3 O-Ring, 1-7/8 ’’ID x 2-1/8 ’’OD 1 Pack of Ten (10) 324486 (11)
11 324486 Body (Brass) 1 324488 (22)
12 Spacer 1 324492 (17)
13 323127 Cup, Packing (Glass-Filled Teflon) 2 324493 (7)
14 Washer (Brass) 1 324494 (9)
15 322164 Washer 1 326069-18 (8)
16 171701-32 Ball, 1/2 ’’Dia. (Stainless Steel) 1 328030 (3)
17 324492 Seat (Stainless Steel) 1 328034 (2)
18 Gasket (Copper) 3 336403 (12)
19 336406 Cylinder (Stainless Steel) 1 336404 (4)
20 336478 Washer, Stop (Stainless Steel) 1 336406 (19)
21 Ball, 7/8 ’’Dia. (Stainless Steel) 1 336442 (6)
22 324488 Body, Valve (Stainless Steel) 1 336478 (20)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
Repair Kit
Part No. Kit Symbol Description
393426-1 Kit, Major Repair

SER 7880-C1 Low-Pressure Pump
Revision (6-00) 4 Alemite Corporation
Figure 3 Delivery versus Discharge Pressure and Air Consumption
Accessories
Performance Curves
A pump’s ability to deliver fluid is based on the pressure (psi/Bars) and quantity
(cfm/lpm) of air supplied to the motor and the amount of fluid discharge [back] pressure to be
overcome within the system. This chart contains curves based on three 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 fluid discharge pressure in psi/Bars (left Y axis).
Part Number Description
338977 16-Gallon Drum Cover (w/ gasket)
318040-4 55-Gallon Drum Cover
325749 Wall Bracket
SWA 306 Siphon Wand Kit
Table 2 Low-Pressure Pump Model 7880-C1 Accessories

Low-Pressure Pump SER 7880-C1
Alemite Corporation 5 Revision (6-00)
Overhaul
NOTE: Refer to Figure 2 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. Accidental dis-
charge of pressure and/or fluid 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 Air Motor Assembly (1) horizontally in a
soft-jaw vise at the wrench flats on the air inlet
body.
2. Unscrew the tube from the air inlet body.
CAUTION
Support the pump tube assembly during
removal. Damage to components can occur.
3. Remove Clip (4) that secures the air motor rod to
Piston Rod (5).
4. Unscrew the pump rod [with attached components]
from the Air Motor’s rod.
• Rotate the entire pump tube assembly.
5. Remove the Air Motor’s tube from Body (11).
Pump Tube Assembly
Body Assembly
6. Remove O-Ring (10) from the Body.
7. Unscrew Packing Screw (6) from the Body.
8. Unscrew Cylinder (19) [with attached components] from
the Body.
9. Remove Piston Rod (5) [with attached components] from
the bottom of the Body.
10. Remove Gasket (18) from the Body.
11. Remove Female Back-Up Ring (7), Packing Rings (8),
and Male Support Ring (9) from the Body.
Piston Rod Assembly
12. Unscrew Seat (17) from the Piston Rod.
• Insert a punch or similar tool through the hole in the
Rod.
13. Remove Ball (16), Spacer (12), Packing Cup (13),
Washer (14), additional Packing Cup (13), and Washer
(15) from the Seat.
Valve Body Assembly
14. Unscrew the Cylinder from Valve Body (22).
15. Remove Gasket (18), Stop Washer (20), additional Gasket
(18), and Ball (21) from the Valve Body.
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 Piston Rod (5) for score marks.
• Replace as necessary.
4. Inspect bore of Cylinder (19) 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 (21) into Valve Body
(22). Fill the Valve Body with solvent. Make
sure no leakage occurs.

SER 7880-C1 Low-Pressure Pump
Revision (6-00) 6 Alemite Corporation
Cylinder
10.Screw the Cylinder into the Body assembly.
• Use care passing the Packing Cups.
• Do not tighten the Cylinder at this time.
Valve Body
11. Install Ball (21), Gasket (18), Stop Washer (20) [flat
side first], and additional Gasket (18) into Valve Body
(22).
12. Screw the Valve Body assembly onto the Cylinder.
• Tighten the Valve Body onto the Cylinder and at the
same time the Cylinder into the Body.
• Make sure to properly crush the Gaskets.
Connect Air Motor to Pump Tube
13. Pull Piston Rod (5) from Body (11) until it seats.
14. Screw the tube of the Air Motor onto the Body of the
pump assembly.
• Do not tighten at this time.
15. Screw the Air Motor’s rod onto Piston Rod (5).
• Make sure the cotter pin holes align.
16. Install Clip (4) that secures the Air Motor’s rod to the
Piston Rod.
17. Make sure the Air Motor’s packing and washer are
seated properly.
18. Screw the Air Motor’s adapter onto the Air Motor’s
tube [with Loctite 222].
• Tighten the adapter securely onto the the tube and at
the same time the tube onto the Body.
Assembly
NOTE: Prior to assembly, certain compo-
nents require lubrication in clean oil. Refer
to Table 3 for details.
Pump Tube Assembly
Body
1. Install O-Ring (10) onto Body (11).
2. Install and seat Male Support Ring (9) [flat side first],
Packing Rings (8) [concave side first], and Female
Back-Up Ring (7) [concave side first] into the Body.
3. Install Packing Screw (6) into the Body until it
contacts the Packing Ring group.
IMPORTANT: The Packing Screw will
require adjustment. Refer to the section enti-
tled Bench Test and Operation for details.
4. Install Gasket (18) into the Body.
5. Clamp the Body in a soft-jaw vise.
Piston Rod and Seat
6. Install Piston Rod (5) into the top of the Body.
• Use care passing the Packing Rings.
7. Position Seat (17) threads upward.
8. Install and seat the following components in order:
•Washer(15) [lip upward] ................................ Qty 1
• Packing Cup (13) [flat side upward] ............... Qty 1
•Washer(14)..................................................... Qty 1
• Packing Cup (13) [flat side first]..................... Qty 1
• Spacer (12) [lip downward]............................. Qty 1
•Ball(16) ......................................................... Qty 1
9. Screw the Seat assembly [with Primer T and
Loctite 242] into the Piston Rod.
• Follow the thread sealant manufacturer’s
recommendations.
• Tighten the Seat securely.
Item No. Description
5 Piston Rod
10 O-Ring, 1-7/8 ’’ID x 2-1/8 ’’OD
19 bore of Cylinder
Table 3 Components Lubricated in Clean Oil

Low-Pressure Pump SER 7880-C1
Alemite Corporation 7 Revision (6-00)
Figure 4 Pump Tube Assembly - Section View
Refer to Figure 2 Parts List
for Parts Identification
Bench Test and Operation
WARNING
Do not exceed the lowest pres-
sure rating of any component in the
system.
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.
Initial Prime
1. Place the pump in the fluid to be
dispensed.
2. Connect a product hose to the pump’s
fluid 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
fluid is free of air.
If the pump assembly does not prime,
refer to the Troubleshooting Chart for
details.

SER 7880-C1 Low-Pressure Pump
Revision (6-00) 8 Alemite Corporation
Starting Pressure
9. Set the air pressure to 25 psi (1.7 Bars).
10. Insert the Adjusting Bar through the slot in the Air
Motor’s tube and into a hole of the Packing Screw.
11. Adjust the Packing Screw until the pump assembly
stops.
12. Loosen the Packing Screw 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 fluid 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. 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.
Part Number Description
5604-2 Moisture Separator
7604-B Regulator and Gauge
Table 4 Air Line Components
Packing Adjustment
IMPORTANT: Break-in and wear of upper
packings require the user to readjust the
Packing Screw:
• after approximately 6 hours of initial operation *
• anytime the upper packings 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. Insert the Adjusting Bar through the slot in the Air
Motor’s tube and into a hole of the Packing Screw.
4. Tighten Packing Screw (6) clockwise 1/4-turn.
5. Set the air pressure to 25 psi (1.7 Bars).
6. Hold the control valve open while aiming into a
suitable collection container.
7. Loosen the Packing Screw until the pump assembly
begins to cycle.
* Applies to new and overhauled pumps.

Low-Pressure Pump SER 7880-C1
Alemite Corporation 9 Revision (6-00)
Changes Since Last Printing
Changed Initial Operating Pressure
Troubleshooting Chart
Pump Indications Possible Problems Solution
Pump does not cycle 1. Packings (8) too tight
2. Air motor not operating properly
3. Pump tube jammed and/or contains
loose components
4. Insufficient air pressure
1. Adjust Packing Screw Assembly (6)
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
fluid pressure for up to one hour
2. See Internal Leaks
3. See External Leaks
4. Correct leak
External Leaks
Product leakage visible at bottom
of Body (11)1. Damaged Gasket (18) 2. Cylinder (19) not sufficiently tight 1. Use Kit 393426-1 2. Tighten Cylinder (19) into Body
(11)
Product leakage at exhaust port in
Air Motor Assembly (1)1. Packing Rings (8) too loose
2. Worn or damaged Packing Ring(s) (8)
3. Worn or damaged Piston Rod (5)
1. Adjust Packing Screw Assembly (6)
2. Use Kit 393426-1
3. Replace Piston Rod (5)
Product leakage between Cylinder
(19) and Valve Body (22)1. Worn or damaged Gaskets (18) 2. Valve Body (22) not sufficiently tight 1. Use Kit 393426-1 2. Tighten Valve Body (22) onto
Cylinder (19)
Internal Leaks
Pump does not prime or cycles
continuously, or slowly (more than
once or twice/hour)
1. Foreign material between Ball (16) and
Seat (17)
2. Foreign material between Ball (21) and
Valve Body (22)
3. Worn or damaged Ball (16)
4. Worn or damaged Seat (17)
5. Worn or damaged Ball (21)
6. Worn or damaged Valve Body (22)
7. Worn or damaged Packing Cups (13)
Locate and eliminate source of foreign
material
Disassemble pump tube, clean,
inspect, and replace worn or damaged
components

SER 7880-C1 Low-Pressure Pump
Revision (6-00) 10 Alemite Corporation
Every effort has been made to ensure that the information within this publication is accurate.
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