Alemite 8702 Series User manual

Service Guide
8702
SER 8702
Alemite LLC
167 Roweland Drive, Johnson City, Tennessee 37601
www.alemite.com
Copyright © 2010 by Alemite LLC
-A1 This document contains confidential information that is the property of Alemite LLC
670978 and is not to be copied, used, or disclosed to others without express written permission. Revision (1-10)
Description
The major components of the 8702 series pumps consist
of an hydraulic reciprocating motor and a double acting pump
tube.
These hydraulic pumps are designed to deliver a range of
light to heavy lubricants directly from their original
container.
The follower tube contains a 1/4 " NPTF (f) inlet to allow
the return of lubricant to the container when relieving system
pressure.
Each pump model is designed with a pump tube length to
accommodate different size containers. See Figure 1.
Specifications
Hydraulic Motor
Pump Tube
Piston Diameter x Stroke Hydraulic
Max. Hydraulic
Pressure
Inches Centimeters psi Bars
1 5/16 x 1-5/8 3.3 x 4.1 1/4 " NPSI (f) 600 41.3
For information on the air motor, refer to Service Guide SER 340952
Material
Outlet
Max. Material
Pressure Max. Delivery/Minute (Approximate)* Displacement per Cycle
psi Bars Ounces Grams in 3cm3
3/8 " NPTF (f) 7500 517 6 454 0.277 4.54
* For detailed information, refer to Figure 3
Table 1 Model 8702 Series Specifications
Figure 1 High-Pressure Hydraulic Pump
Model 8702 Series
High-Pressure Hydraulic Pump
Pump Model Container Size X Y
lbs kg Inches Cm Inches Cm
8702-A 35 20 19 48.3 29-1/2 75
8702-B 120 50 27-3/4 70.5 38-1/4 97.2
8702-C 400 180 37 94 47-1/2 120.7
Hydraulic

SER 8702 High-Pressure Hydraulic Pump
Revision (1-10) 2 Alemite LLC

High-Pressure Hydraulic Pump SER 8702
Alemite LLC 3 Revision (1-10)
Item
No. Part No. Description Qty Notes Numeric Order Part # (Item #)
3 Motor Assembly, Hydraulic 1 See SER 340952 51017 (6)
4 X171013-12 O-Ring, 1-1/8 " ID x 1-1/4 " OD 1 Pack of Ten (10) 131168 (30)
5 324805 Adapter 1 170292 (1)
6 51017 Gasket (Aluminum) 4 170772 (34)
7 320974 Coupling 1 X171001-23 (33)
8 320971 Pin, 0.088 " Dia. x 41/64 " Long 1 X171013-12 (4)
9 320975 Pin, 0.120 " Dia. x 41/64 " Long 2 171700-12 (15)
10 320704-9 Rod, 9 " Long 1 Model 8702-A 172190-9 (21)
320704-1 Rod, 17-3/4 " Long 1 Model 8702-B 172190-10 (26)
320704-3 Rod, 27 " Long 1 Model 8702-C 317536 (16)
11 320705 Coupling 1 317549 (25)
12 320718 Stop, Ball 1 320704-1 (10)
13 321605 Washer 1 320704-3 (10)
14 320719 Spring, 0.75 " Long 1 320704-9 (10)
15 171700-12 Ball, 3/16 " Dia. 1 320705 (11)
16 317536 Washer, Locking 1 320706 (36)
17 330332 Piston 1 320712 (32)
18 337392-4 Tube, 12-1/2 " Long 1 Model 8702-A 320713 (31)
337392 Tube, 21-1/4 " Long 1 Model 8702-B 320716 (28)
337392-2 Tube, 30.42 " Long 1 Model 8702-C 320718 (12)
19 Bearing (Brass) 1 320719 (14)
20 337391 Retainer 1 320971 (8)
21 Seal, 0.540 " ID x 0.914 " OD 1 320974 (7)
22 Bearing (Brass) 1 320975 (9)
23 Gasket (Aluminum) 1.08 " ID 1 321085 (2)
24 337388 Extension 1 321605 (13)
25 317549 Washer, Stop 1 324300-5 (3)
26 Seal, 0.282 " ID x 0.532 " OD 1 324805 (5)
27 337995 Body, Valve 1 330329 (29)
28 320716 Seat, Valve 1 330332 (17)
29 330329 Rod, 3.91 " Long 1 330334 (23)
30 131168 Pin, 1/16 " Dia. x 0.50 " Long 1 337388 (24)
31 320713 Disc, Primer 1 337389 (22)
32 320712 Nut, Elastic Stop, 12- 28 1 337391 (20)
33 X171001-23 O-Ring, 1-1/4 " ID x 1-1/2 " OD 1 Pack of Ten (10) 337392 (18)
34 Setscrew, 10-32 x 3/16 " 1 337392-2 (18)
35 382723-C1 Tube, Follower, 17-7/16 " Long 1 Model 8702-A 337392-4 (18)
382723-A1 Tube, Follower, 26-1/4 " Long 1 Model 8702-B 337393 (19)
382723-B1 Tube, Follower, 35-1/2 " Long 1 Model 8702-C 337995 (27)
36 320706 Body, Primer 1 382723-A1 (35)
382723-B1 (35)
382723-C1 (35)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item
Repair Kits
Part No. Kit Symbol Description
393514 Kit, Major Repair
393530-9 Kit, Seal [includes five (5) of item number 21]
393530-10 Kit, Seal [includes five (5) of item number 26]

SER 8702 High-Pressure Hydraulic Pump
Revision (1-10) 4 Alemite LLC
Accessories
Model Number Container Size Follower Cover Collar Bung Adapter
8702-A 35 lbs/20 kg 337665 338166
340090 3267508702-B 120 lbs/50 kg 338993 338371
8702-C 400 lbs/180 kg 338911 338163
Table 2 8702 Model Series Accessories
Hydraulic
Hydraulic
Hydraulic
Hydraulic

High-Pressure Hydraulic Pump SER 8702
Alemite LLC 5 Revision (1-10)
IMPORTANT: 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-trichlo-
roethane in this pump. An explosion can result
within an enclosed device capable of containing
pressure when aluminum and/or zinc-plated parts
in the pump come in contact with halogenated
hydrocarbon solvents.
Release all pressure within the system prior to
performing any overhaul procedure.
• Disconnect the hydraulic 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.
Overhaul
NOTE: Refer to Figure 2 for component
identification on all overhaul procedures.
Disassembly
1. Loosen Setscrew (34) that secures Follower Tube (35)
to Adapter (5).
• Remove the Follower Tube from the Pump.
2. Remove O-Ring (33) from the Follower Tube.
3. Secure the pump assembly in a soft-jaw vise at
Adapter (5).
4. Extend Rod (29) from Primer Body (36).
5. Gently remove Nut (32) from the Rod.
• Use an appropriate size punch in the hole of the Rod
to prevent rotation. See Figure 2.
6. Remove Primer Disc (31) from the Rod.
7. Push the Rod into the Primer Body.
Pump Tube (Outer Components)
8. Rotate the Primer Body.
• Use a large wrench or other suitable tool.
NOTE: The pump tube will break at one of
three places. Unscrew the separated portion
from the fastened components of the pump
tube assembly.
9. Unscrew the hydraulic motor from Adapter (5).
• Rotate the hydraulic motor assembly.
10. Remove O-Ring (4) from the Adapter.
NOTE: If the pump was not leaking at the
top of Tube (18), do not separate the Adapter
from the Tube. Components are locked with
Loctite 222.
11. Unscrew Tube (18) from the Adapter as required.
• Remove Gasket (6).
12. Clamp Retainer (20) horizontally in a soft-jaw vise.
13. Unscrew the Primer Body from Extension (24).
IMPORTANT: Remove Valve Seat (28)
squarely from the Primer Body. Should the
Valve Seat cock during removal, realign and
start again. Gasket (6) may interfere.
14. Remove Valve Seat (28) from the Primer Body.
15. Remove Gasket (6) from the Valve Seat.
16. Unscrew the Extension from the Retainer.
17. Remove Gasket (23) from the Extension.
18. Remove Valve Body (27) from the Extension.
• Remove Stop Washer (25).
19. Remove Seal (26) from the Valve Body.
20. Remove Bearing (22) and Seal (21) from the Retainer.
21. Unscrew Tube (18) from the Retainer.
22. Remove Gasket (6), Bearing (19), and additional
Gasket (6) from the Retainer.

SER 8702 High-Pressure Hydraulic Pump
Revision (1-10) 6 Alemite LLC
Item No. Description
4 O-Ring, 1-1/8 " ID x 1-1/4 " OD
21 Seal, 0.540 " ID x 0.914 " OD
26 Seal, 0.282 " ID x 0.532 " OD
33 O-Ring, 1-1/4 " ID x 1-1/2 " OD
Table 3 Lubricated Components
Pump Tube (Inner Components)
23. Remove Pin (8) that secures Coupling (7) to the
hydraulic motor rod.
• Unscrew the Coupling assembly from the hydraulic
motor rod.
24. Clamp Coupling (11) in a soft-jaw vise.
25. Remove upper Pin (9) that secures Coupling (7) to Rod
(10).
• Unscrew the Rod from the Coupling.
26. Remove lower Pin (9) that secures Coupling (11) to the
Rod.
• Unscrew the Rod from the Coupling.
27. Remove Pin (30) that secures Piston (17) to Rod (29).
• Unscrew the Rod from the Piston.
28. Straighten the tabs on Locking Washer (16).
29. Unscrew Piston (17) from the Coupling.
30. Remove the Locking Washer from the Piston.
31. Remove Ball (15) from the Piston.
32. Remove Spring (14) and Washer (13) from Ball
Stop (12).
NOTE: Separate the Ball Stop from the
Coupling only if the connection is loose.
33. Unscrew the Ball Stop from the Coupling as needed.
Clean and Inspect
NOTE: Use the appropriate repair kit for
replacement parts. Make sure all the compo-
nents are included in the kit and in good con-
dition before discarding used parts.
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 (17) closely. Use a magnifying glass to
detect any wire draw marks.
• Replace as necessary.
4. Closely inspect the mating surfaces of all components
for any imperfections. Ensure a smooth and clean
contact is obtained when assembled.
EXAMPLE: Place Ball (15) into Piston
(17). Fill the Piston with solvent. Make sure
no leakage occurs.
Assembly
NOTE: Prior to assembly, certain compo-
nents require lubrication in clean oil. Refer
to Table 3 for details.
Pump Tube (Inner Components)
NOTE: Refer to Figure 4 for a section view
of the pump tube assembly.
1. Place Ball (15) into Piston (17).
NOTE: If the Ball Stop was previously
locked with Loctite 242, skip procedure 2.
2. Screw and seat Ball Stop (12) [with Loctite 242] into
Coupling (11) as needed.
• Follow the thread sealant manufacturer’s
recommendations.
• Tighten securely.
3. Install Washer (13) and Spring (14) onto the Ball Stop.
4. Position Locking Washer (16) into the groove on the
Piston.
5. Screw the Coupling assembly into the Piston.
• Tighten from 19 to 21 foot pounds (25.4 - 28.3 Nm).
• Continue to tighten and align the nearest flat of the
Coupling with the tabs on the Locking Washer as
necessary.
IMPORTANT: Press on the Ball to ensure it
moves a minimum of 1/8 " (3.2 mm) prior to
contact with the Ball Stop. Should the value
be less, check to ensure the Ball Stop is fully
seated in the Coupling.
6. Bend the tabs of the Locking Washer upward onto the
Coupling.
7. Screw Rod (29) into the Piston until the pin holes
align.
NOTE: Use a spot of grease on all pins to
prevent movement.

High-Pressure Hydraulic Pump SER 8702
Alemite LLC 7 Revision (1-10)
Figure 4 Pump Tubes 337384-H1, -D1, and -E1 - Section View
8. Install Pin (30).
9. Screw Rod (10) into Coupling (11)
until the pin holes align.
• Install Pin (9).
10. Screw Coupling (7) [center hole
first] onto the Rod until the pin
holes align.
• Install additional Pin (9).
11. Secure the hydraulic motor
assembly in a soft-jaw vise.
12. Screw the Coupling assembly onto
the hydraulic motor rod until the
pin holes align.
• Install Pin (8).
13. Install and seat Seal (21) [lips first]
into the bottom of Retainer (20).
See Figure 2.
14. Install and seat Bearing (22) into
the bottom of the Retainer.
15. Install Gasket (23) onto the top of
Extension (24).
16. Screw the Extension (Gasket end
first) into the bottom of the
Retainer.
• Do not tighten at this time.
17. Install Gasket (6) into the top of
the Retainer.
18. Install and seat Bearing (19) [small
diameter first] and additional
Gasket (6) into the top of the
Retainer.
19. Screw Tube (18) into the top of the
Retainer.
• Do not tighten at this time.
20. Install and seat Gasket (6) into
Adapter (5).
IMPORTANT: If a
primer is used with Loc-
tite 222, the curing time
is greatly reduced.
Refer to Figure 2 Parts List
for Parts Identification
Pump Tube (Outer Components)

SER 8702 High-Pressure Hydraulic Pump
Revision (1-10) 8 Alemite LLC
21. Screw the Tube assembly [with Loctite 222] into the
Adapter.
• Follow the thread sealant manufacturer’s
recommendations.
• Do not tighten at this time.
22. Install O-Ring (4) onto the Adapter.
23. Apply grease to Piston (17).
• This will aid the installation process.
CAUTION
Install the outer component assembly onto the
inner assembly with care. Damage to Seal (21) can
occur.
24. Install the outer component assembly onto the inner
assembly.
• Use a slight twisting motion to pass the Seal.
• At the same time thread theAdapter into the base of
the air motor.
IMPORTANT: Make sure the flange portion
of the Adapter seats flush against the base of
the motor. Should a gap exist, inspect the
components of the air motor packing group.
25. Install Stop Washer (25) into the Extension.
26. Install and seat Seal (26) [heel end first] into Valve
Body (27).
27. Install the Valve Body assembly (Seal first) onto
Rod (29).
• Make sure the Valve Body assembly seats properly
in the Extension.
28. Install and seat Valve Seat (28) [large diameter first]
into Primer Body (36).
29. Install and seat Gasket (6) into the Primer Body.
30. Screw the Primer Body onto the Extension.
31. Place a large wrench or other suitable tool into the slot
of the Primer Body.
• Tighten all the components of the assembly securely.
• Crush all Gaskets.
32. Extend Rod (29) from the Primer Body.
33. Install Primer Disc (31) onto the Rod.
34. Gently screw Nut (32) onto the Rod.
• Use an appropriate size punch in the hole of the Rod
to prevent rotation. See Figure 2.
• Do not overtighten.
35. Install O-Ring (33) into Follower Tube (35).
36. Install the Follower Tube onto the Pump.
37. Tighten Setscrew (34) that secures the Follower Tube
to the Adapter.

SER 8702 High-Pressure Hydraulic Pump
Revision (1-10) 9 Alemite LLC

SER 8702 High-Pressure Hydraulic Pump
Revision (1-10) 10 Alemite LLC

High-Pressure Hydraulic Pump SER 8702
Alemite LLC 11 Revision (1-10)
Troubleshooting Chart
Pump Indications Possible Problems Solution
Pump does not cycle 1. Hydraulic motor not operating properly
2. Pump tube jammed and/or contains loose
components
3. Insufficient hydraulic pressure
1. Inspect hydraulic motor and rebuild
or replace as necessary
2. Rebuild pump tube
3. Increase hydraulic pressure
Pump will not prime 1. Excessive cycling speed
2. Pump leaking internally 1. Reduce hydraulic pressure 2. See Internal Leaks
Pump cycles rapidly Product source empty Replenish product
Pump cycles continuously, or
slowly (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 visible at top
of Adapter (5)1. Initial tightening of Adapter (5) to Hydraulic Motor Assembly (3) not
sufficient
2. Damaged O-Ring (4)
1. Tighten Adapter (5) into Hydraulic
Motor Assembly (19)
2. Replace O-Ring (4)
Product leakage at the
sections of the pump tube
[This requires the removal of
Follower Tube (35)]
1. Initial tightening of Tube (18) to Adapter
(5) not sufficient
2. Initial tightening of Tube (18) to
Retainer (20) not sufficient
3. Initial tightening of Extension (24) to
Retainer (20) not sufficient
4. Initial tightening of Extension (24) to
Primer Body (36) not sufficient
5. Gasket(s) (6) worn or improperly
crushed
6. Gasket (23) worn or improperly crushed
1. Tighten Tube (18) into Adapter (5)
2. Tighten Tube (18) into Retainer (20)
3. Tighten Extension (24) into
Retainer (20)
4. Tighten Extension (24) into Primer
Body (36)
5. Replace Gasket(s) (6)
6. Replace Gasket (23)
Internal Leaks
Pump does not prime or
cycles continuously, or slowly
(once or twice/hour)
1. Foreign material between Ball (15) and
seat in Piston (17)
2. Foreign material between Valve
Body (27) and Valve Seat (28)
3. Worn or damaged Ball (15)
4. Worn or damaged Piston (17)
5. Worn or damaged Spring (14)
7. Worn or damaged Valve Body (27)
8. Worn or damaged Valve Seat (28)
9. Worn or damaged Seal (21)
10. Worn or damaged Seal (26)
11. Worn or damaged Rod (29)
1. Locate and eliminate source of
foreign material.
2. Disassemble pump tube, clean,
inspect, and replace worn or
damaged components.
Changes Since Last Printing
Initial Release

SER 8702 High-Pressure Hydraulic Pump
Revision (1-10) 12 Alemite LLC