OWNER’S TECHNICAL MANUAL

7785-A5

Service Guide
High-Pressure Grease Pump
7785-A5
Description 7785-B5
The major components of the pump models in the 7785 series consist of an air-operated motor and a pump tube.
The air motor connects directly to the double-acting reciprocating pump tube. These high-pressure grease pumps
are designed to deliver a range of greases (up to NLGI # 3) and operate directly from their original drums or bulk

High-Pressure Grease Pump

containers.* Each pump model is designed with a pump tube length to accommodate different size containers.
See Figure 1.

Description
Service Guide
The major components of the pump models in the 7785 series
consist of an air-operated motor and a pump tube. The air motor
7785-A5
7785-B5
connects directly to the double-acting reciprocating pump tube. Air
Exhaust

High-Pressure Grease Pump

These high-pressure grease pumps are designed to deliver a
range of greases (up to NLGI # 3) and operate directly from their
original drums or bulk containers.*
Description
Models 7785-A5 and 7785-B5
Air Inlet

Each
Thepump
majormodel is designed
components with amodels
of the pump pump in
tube
the length to
7785 series Material
accommodate
consist of andifferent sizemotor
air-operated containers. See Figure
and a pump 1. air motor
tube. The Outlet
connects directly to the double-acting reciprocating pump tube. Air

Specifications
Exhaust
These high-pressure grease pumps are designed to deliver a
range of greases (up to NLGI # 3) and operate directly from their
original drums or bulk containers.*
Air Motor Air Inlet
Models 7785-A5 and 7785-B5
Piston Diameter / Stroke Max. Air
Each pump modelAiris Inlet
designed with a Pressure
/ Outlet pump tube length to
Material Material
Outlet
accommodate
Inches
different
Centimeters
size containers. See
psi
Figure
Bars
1. Outlet

Specifications
4-1/4 / 4 10.8 / 10.2 3/4 " NPTF (f) 200 14 1/2 " NPTF (f) Y
Specifications
For information on the air motor, refer to Service Guide SER 323440-4

Air Motor
Pump Tube
X

Max. Air
Piston Diameter / Stroke
Max. Material Delivery/Minute Pressure Material
Displacement/Cycle
Pressure Air Inlet / Outlet
(Approximate)*
Ratio Outlet
Inches Centimeters psi Bars
psi Bars Pounds Kilograms Inches 3 Centimeters 3
4-1/4 / 4 10.8 / 10.2 3/4 " NPTF (f) 200 14 1/2 " NPTF (f) Y
40:1 8,000 552 13 6 2.45 40.15
For information on the air motor, refer to Service Guide SER 323440-4
* For detailed information, refer to Figure 3 Material Inlet X
Pump Tube
Table 1 7785 Model Series Specifications
Container Model X Y
Max. Material Delivery/Minute Pump Size Weight
Displacement/Cycle
Pressure (Approximate)* Model
Ratio
lbs kg lbs kg Inches Cm Inches Cm
psi Bars Pounds Kilograms 3 3
* Pump model 7785-A5 is operated in various
Inches type systems,
Centimeters
7785-A5 400 180 77 35 33-1/8 84 52-1/4 133
Refer40:1
to the8,000 entitled13Alternate
section552 6 Installation
2.45 for details.
40.15
7785-B5 120 72 33 25-5/8 65 44-3/4 114
* For detailed information, refer to Figure 3
Figure 1Material
High-Pressure
Inlet Grease Pump
Table 1 7785 Model Series Specifications Models 7785-A5 and 7785-B5
NSW QLD/PNG VIC/TAS WA Container SA/NT
Model NZ
X Y
TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 Pump
TEL: (08) 9209 3066 Size TEL:Weight
(08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 Alemite
FAX: (03) 8787 8266Corporation Model
FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008
lbs kg lbs kg Inches Cm Inches Cm
PO Box 473515, Charlotte, North Carolina 28247-3515
* Pump model 7785-A5 is operated in various type systems, 7785-A5 400 180 77 35 33-1/8 84 52-1/4 133
Visit our website at www.alemlube.com.au or www.alemlube.co.nz
Refer to the section entitled Alternate Installation
Copyright for details.
© 1995 by Alemite Corporation 7785-B5 120 72 33 25-5/8 65 44-3/4 114
SER 7785-A5 Parts And Drawing Breakdown For The 7785-A5
High-Pressure Grease Pump

2
5
13 3
14 4
15 1

16

17

18 6

19

20

21

20

22

10

11

12 8

Figure 2-A High-Pressure Grease Pump Model 7785 Series - Exploded View

Revision
NSW (8-97) QLD/PNG VIC/TAS 2 WA SA/NT Alemite
NZ Corporation
TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 TEL: (08) 9209 3066 TEL: (08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

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 Parts And Drawing Breakdown For The 7785-A5
High-Pressure Grease Pump SER 7785-A5

Item Numeric Order

Part No. Description Qty Notes
No. Part # (Item #)
1 10522 Plug, Square Head Pipe, 1/4 " NPTF (m) 1 10522 (1)
2 327706 Adapter, 1/2 " NPTF (m) 1 171009-13 (13)
3 323419 Washer, 1.29 " OD 1 171009-33 (9)
4 324274 Bushing (Rubber) 1 171009-35 (10)
5 323842 Bolt, Eye, 3/8 " NPTF (m) 1 172190-5 (15)
6 Motor Assembly, Air 1 See SER 323440-4 172190-6 (17)
7 328037 Connector, 3/4 " NPTF (m) 1 323419 (3)
8 328031 Coupler Air, 1/2 " NPTF (f) 1 323440-4 (6)
9 171009-33 O-Ring, 1-13/16" ID x 2 " OD 1 323693 (20)
10 171009-35 O-Ring, 1-15/16" ID x 2-1/8 " OD 1 323786 (11)
11 323786 Body 1 323787 (12)
12 323787 Screw, Cap, Socket Head, 1/2 " - 13 3 323842 (5)
13 O-Ring, 1-3/16" ID x 1-5/16 " OD 1 324274 (4)
14 Spacer 1 327706 (2)
15 Seal, 0.812 " ID x 1.062 " OD 1 328031 (8)
16 Ring, Lantern (Brass) 1 328037 (7)
17 Seal, 0.812 " ID x 1.562 " OD 1 332465 (21)
18 337361 Washer, 1.55 " OD 1 332466 (19)
19 332466 Spacer 1 333256 (22)
20 323693 Gasket (Aluminum) 2 337361 (18)
21 332465 Washer, 1.93 " OD 1 337362 (16)
22 333256 Nut, Jam, 2.00 - 16 UN - 2B 1 337363 (14)
Legend:
Part numbers left blank (or in italics) are not available separately
designates a repair kit item

Repair Kits

Part No. Kit Symbol Description Notes

398988-2 Kit, Major Repair Includes items on Figure 2-A and 2-B
393622 Kit, Minor Repair (for Pump Tube Assembly) Includes items on Figure 2-A and 2-B
393040-1 Kit, Minor Repair (for Body and Seal Group)
393530-5 Kit, Seal [includes five (5) of item number 15]
393530-6 Kit, Seal [includes five (5) of item number 17]

Alemite Corporation 3 Revision (8-97)

NSW QLD/PNG VIC/TAS WA SA/NT NZ
TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 TEL: (08) 9209 3066 TEL: (08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

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SER 7785-A5 Parts And Drawing Breakdown For The 7785-A5
High-Pressure Grease Pump

41
33

34
42 26

43 35

36 24
44
37
45 27

23
44
38 24
28
46
39

29
27
30
47 40
31 25

27
27
48

49 32

24
23

24

50

Figure 2-B High-Pressure Grease Pump Model 7785 Series - Exploded View

Revision
NSW (8-97) QLD/PNG VIC/TAS 4 WA SA/NT Alemite
NZ Corporation
TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 TEL: (08) 9209 3066 TEL: (08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

Visit our website at www.alemlube.com.au or www.alemlube.co.nz 4

High-Pressure Grease Pump SER 7785-A5
Parts And Drawing Breakdown For The 7785-A5
Item Numeric Order
Part No. Description Qty Notes
No. Part # (Item #)
23 323439 Coupling 2 18850 (49)
24 324648 Clip, Spring 4 50666 (37)
323438-22 Rod, Pump Tube, 13.25 " Long 1 Model 7785-A5 131402 (27)
25
323438-23 Rod, Pump Tube, 5.75 " Long 1 Model 7785-B5 131398-1 (47)
333257-1 Tube, Pump, 22.25 " Long 1 Model 7785-A5 171032-9 (39)
26
333257-3 Tube, Pump, 14.75 " Long 1 Model 7785-B5 171700-32 (36)
27 131402 Gasket, 1.68 " OD (Aluminum) 4 172190-8 (45)
28 337380 Barrel Assembly 1 172190-7 (30)
29 Ring, Wear (Glass-Reinforced Nylon) 1 323438-22 (25)
30 Seal, 1.00 " ID x 1.375 " OD 1 323438-23 (25)
31 Bearing (Brass) 1 323439 (23)
32 Spacer 1 323717 (34)
33 332246 Piston 1 323732 (38)
34 323717 Stop, Ball 1 323734 (48)
35 327705 Spring, 1-1/2 " Long Straight 1 323738 (46)
36 Ball, 1/2 " Dia. 1 323741 (43)
37 50666 Washer, 0.87 " OD (Aluminum) 1 323742 (42)
38 323732 Adapter and Insert Assembly 1 323747-2 (41)
39 171032-9 Pin, Roll, 3/32 Dia. x 3/4 " Long 1 324648 (24)
40 333342 Rod, Primer 1 327705 (35)
41 323747-2 Adapter 1 332246 (33)
42 323742 Washer, Guide 1 333085 (50)
43 323741 Screw, 1.00 " 1 333257-1 (26)
44 Washer, 0.93 " OD (Nylon) 2 333257-3 (26)
45 Seal, 0.50 " ID x 0.950 " OD 1 333342 (40)
46 323738 Body, Valve 1 337376 (32)
47 131398-1 Seat, Valve 1 337377 (31)
48 323734 Plate 1 337378 (44)
49 18850 Nut, Elastic Stop, 1/4 " - 28 1 337379 (29)
50 333085 Body, Primer 1 337380 (28)
Legend:
Part numbers left blank (or in italics ) are not available separately
designates a repair kit item

Repair Kits
Part No. Kit Symbol Description Notes
398988-2 Kit, Major Repair Includes items on Figure 2-A and 2-B
393622 Kit, Minor Repair (for Pump Tube Assembly) Includes items on Figure 2-A and 2-B
394077-1 Kit, Minor Repair (for Lower Pump Tube Packing)
393530-7 Kit, Seal [includes five (5) of item number 30]
393530-8 Kit, Seal [includes five (5) of item number 45]

Alemite Corporation 5 Revision (8-97)

NSW QLD/PNG VIC/TAS WA SA/NT NZ
TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 TEL: (08) 9209 3066 TEL: (08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

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SER 7785-A5 Parts And Drawing Breakdown ForHigh-Pressure
The 7785-A5 Grease Pump

Accessories
Model Number Air Hose Material Hose Follower Cover Union Bung Adapter Muffler

7785-A5 338912 323847-4

317811-5 317882-7 321155 326750-B1 324170
7785-B5 338804 323800-4

Table 2 7785 Model Series Accessories

Preventive Maintenance
Refer to section entitled Overhaul for the procedures necessary to perform maintenance.

Daily Weekly Monthly Yearly

Wipe Exterior with Clean Cloth Inspect for Air and/or Material Leakage

Table 3 7785 Model Series Preventive Maintenance Schedule

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
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).

Bars psi NLGI 2 Grease at 75 F (24 C) cfm lpm

550 8000 200

150 psi (10.3 Bars)
5500
500
7000 175 5000
450
150 psi (10.3 Bars)
150 4500
6000
Material Discharge Pressure

400
4000
Air Consumption

350 5000 125

100 psi (6.9 Bars) 3500
300 100 psi (6.9 Bars)
4000 100 3000
250 2500
200 3000 75
2000
50 psi (3.4 Bars)
150 50 psi (3.4 Bars)
2000 50 1500
100 1000
1000 25
50 500
0 0
0 4 8 12 16 20 24 Pounds/Minute
Legend:

Air Pressure
10 20 30 40 50 Kilograms/Minute
Air Consumption
Material Discharge Pressure
Delivery

Figure 3 Delivery versus Discharge Pressure and Air Consumption

RevisionNSW
(8-97) QLD/PNG VIC/TAS 6 WA SA/NT Alemite Corporation
NZ
TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 TEL: (08) 9209 3066 TEL: (08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

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 Parts And Drawing Breakdown For The 7785-A5
High-Pressure Grease Pump SER 7785-A5

Overhaul Disassembly
1. Unscrew Adapter (2) from the air motor housing.
NOTE: Refer to Figure 2-A and 2-B for
component identification on all overhaul 2. Remove Washer (3) and rubber Bushing (4).
procedures.
Separate Pump Tube from Air Motor
Prior to performing any maintenance procedure, the
following safety precautions must be observed. Personal 3. Clamp the motor housing horizontally in a vise.
injury may occur.
4. Loosen Jam Nut (22) that secures the Pump Tube
assembly to the Air Motor assembly (6).

WARNING
CAUTION
Do not use halogenated hydrocarbon
solvents such as methylene chloride or 1,1,1- Support the Pump Tube assembly during removal.
trichlorethane in this pump. An explosion can Damage to components can occur.
result when aluminum and/or zinc-plated parts in
the pump come in contact with halogenated
hydrocarbon solvents. 5. Unscrew Pump Tube (26) [with attached components]
from the Air Motor.
Release all pressure within the system prior to 6. Pull on the Pump Tube to expose Coupling (23).
performing any overhaul procedure.
• Disconnect the air supply line from the pump 7. Remove upper Spring Clip (24) that secures Pump
motor. Tube Rod (25) to Coupling (23).
• Into an appropriate container, operate the
control valve to discharge remaining pressure 8. Unscrew the Coupling from the air motor piston rod.
within the system. • Rotate the entire Pump Tube assembly.

Never point a control valve at any portion of your Pump Tube Upper Packing
body or another person. Accidental discharge of 9. Unscrew Cap screws (12) that secure Body (11) to the
pressure and/or material can result in injury. Air Motor.
Read each step of the instructions carefully. Make • Do not remove the Cap Screws from the Body.
sure a proper understanding is achieved before
10. Remove the Body from the Air Motor.
proceeding.
• Use the Cap Screws as levers.

11. Position the Body on the bench with the larger

diameter facing upward.
Removal
12. Remove aluminum Gasket (20), Washer (21), and
NOTE: These model pumps are used in
additional Gasket (20) from the Body.
numerous applications and are mounted
accordingly. The following procedures 13. Remove Spacer (19), Washer (18), and Seal (17).
consider the pump assembly to be mounted
to a container with a cover. 14. Remove Lantern Ring (16) with Seal (15), and
Spacer (14).
1. Remove the cover and pump assembly from its • Remove the Seal from the Lantern Ring.
container.
15. Remove O-Ring (13), O-ring (9), and O-Ring (10)
2. Remove the four bolts that secure the pump assembly from the Body.
to the cover.
Pump Tube
IMPORTANT: Remove the follower from the
bottom of the container. 16. Clamp the pump tube assembly at Adapter (41)
securely in a soft-jaw vise.

NSW QLD/PNG VIC/TAS WA SA/NT NZ

Alemite Corporation
TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 7 TEL: (08) 9209 3066 TEL: (08) 8241 7111 Revision
TEL: (09) 447 (8-97)
1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

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SER 7785-A5 Parts And Drawing Breakdown For The 7785-A5
High-Pressure Grease Pump

17. Unscrew and remove Tube (26) from the Adapter. 31. Unscrew Primer Rod from Adapter and Insert
assembly.
18. Remove upper and lower Spring Clips (24) that secure
Pump Tube Rod (25) to upper and lower 32. Remove Valve Body (46) [with attached components]
Couplings (23). and Guide Washer (42) from the upper end of the
Primer Rod assembly.
19. Unscrew the Rod from both Couplings.
33. Remove Screw (43), nylon Washer (44), Seal (45) and
IMPORTANT: Should the pump contain the additional Washer (44) from the Valve Body.
obsolete piston (see Figure 5), and stall
properly, certain parts within the major repair 34. Unscrew the Adapter and Insert assembly from
kit are discarded. If the new piston is required, Piston (33).
order Barrel (28) and Piston (33) separately.
35. Remove aluminum Washer (37), Ball (36), Spring
20. Remove lower Spring Clip (24) that secures Piston (35), and Ball Stop (34) from the Piston.
(33) to lower Coupling (23).

21. Unscrew the Coupling from the Piston.

Clean and Inspect
22. Remove Barrel (28) from the Piston. NOTE: Use the appropriate repair kit for
r e p l a c e m e n t p a r t s . M a ke s u r e a l l t h e
23. Remove both aluminum Gaskets (27). components are included in the kit before
discarding used parts.
24. Remove brass Bearing (31), Seal (30), and nylon Wear
Ring (29) from the Barrel. 1. Clean all metal parts in a modified petroleum-based
solvent. The solvent should be environmentally safe.
25. Unscrew Primer Body (50) from Adapter (41).
2. Inspect all parts for wear and/or damage.
26. Remove the Primer Rod (with attached components) • Replace as necessary.
from the bottom of the Adapter.
3. Inspect Piston (33) and Primer Rod (40) closely. Use a
27. Remove Spacer (32) from top of Adapter. magnifying glass to detect any score marks.
28. Remove Stop Nut (49) from Primer Rod (40). • Replace as necessary.
• Support the Primer Rod through the hole as needed. 4. Closely inspect the mating surfaces of all check valve
29. Remove Plate (48), Gasket (27), Valve Seat (47), and components for any imperfections Ensure a smooth
additional Gasket (27) from the Primer Rod assembly. and clean contact is obtained when assembled.

Assembly
CAUTION
N O T E : P r i o r t o a s s e m b l y, c e r t a i n
Support the Piston and Primer Rod assembly
components require lubrication in clean oil.
during Roll Pin (39) removal. Damage to
Refer to Table 4 for details.
components can occur.

30. Remove Roll Pin (39) that secures Adapter and Insert
assembly (38) to Primer Rod (40).
• Use a punch and a small hammer.

Item No. Item No.

Description Description
on Figure 2-A on Figure 2-B

9 O-Ring, 1-13/16 " ID x 2 " OD 29 Ring, Wear (Glass-Reinforced Nylon)

10 O-Ring, 1-15/16 " ID x 2-1/8 " OD 30 Seal, 1.00 " ID x 1.375 " OD
13 O-Ring, 1-3/16 " ID x 1-5/16 " OD 45 Seal, 0.50 " ID x 0.950 " OD
15 Seal, 0.812 " ID x 1.062 " OD
17 Seal, 0.812 " ID x 1.562 " OD

Table 4 Lubricated Components

Revision
NSW (8-97) QLD/PNG VIC/TAS 8 WA SA/NT Alemite
NZ Corporation
TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 TEL: (08) 9209 3066 TEL: (08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

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 Parts And Drawing Breakdown For The 7785-A5
High-Pressure Grease Pump SER 7785-A5

Pump Tube Upper Packing

NOTE: Refer to Figure 4 for a section view
Air Motor
of the upper packing components.
Piston Rod 14
9
1. Install O-Ring (9) and O-Ring (10) onto Body (11). 13
15
2. Position the Body with the large diameter upward. 16
17
3. Install O-Ring (13) into the Body.
18
10
4. Install Spacer (14) into the Body.
• Make sure the Spacer centers and seats properly. 19

5. Install Seal (15) [lip end first] into Lantern Ring (16). 11
12
6. Install the Lantern Ring assembly into the Body.
20
• Make sure the assembly centers and seats properly. 21
20
7. Install and seat Seal (17) [heel end first] into the Body.
24

CAUTION 22
Do not place Washer (18) inside Spacer (19). 23
Damage to components will occur. 25
26

8. Install Washer (18) and Spacer (19) into the Body. Refer to Figure 2-A Parts List
13
9. Lubricate the air motor piston rod with grease. for Parts Identification
16
11
10. Install the Body assembly (while holding the Spacer in
place) 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 air motor housing.

NOTE: Refer to Figure 2-A for

steps 12 and 13.

12. Install Washer (3) and Bushing (4) onto Adapter (2).

13. Install the Adapter assembly into the Body.

• Do not tighten.

14. Install Cap Screws (12) that secure the Body to the air
motor.
• Tighten each Cap Screw securely.

15. Tighten the Adapter assembly into the Body.

16. Install aluminum Gasket (20), Washer (21), and

additional Gasket (20) into the Body.
Weep Hole
• Make sure the components maintain their position. Grease Travel

Figure 4 Upper Packing - Section View

Alemite
NSW
Corporation QLD/PNG VIC/TAS
9 WA SA/NT
Revision
NZ
(8-97)
TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 TEL: (08) 9209 3066 TEL: (08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

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SER 7785-A5 Parts And Drawing Breakdown For The 7785-A5
High-Pressure Grease Pump

Pump Tube
NOTE: Refer to Figure 5 for cross section
view of pump tube components.

17. Clamp the flats of Piston (33) into a soft-jaw vise.

• Make sure the Piston bore points upward. 23
24
18. Install Ball Stop (34) [flange end first] into the Piston.
• Make sure the Retainer centers and seats properly. 24

19. Install Spring (35) into the Piston.

25
20. Install Ball (36) into the Spring.
26
21. Install Washer (37) onto Adapter and Insert
assembly (38).
27
22. Screw the Adapter and Insert assembly 29
(with Loctite 222) into the Piston. See Figure 2-B.
28
• Tighten securely.

23. Install Washer (44) into Valve Body (46). 30

31
27
CAUTION 32
Use care seating Seal (45) into the Valve Body. 33
Damage to the Seal can occur.

Early Model
24. Install and seat Seal (45) [heel end first] into the Valve Piston Configuration
Body. (No Packings - Obsolete)
34
25. Install additional Washer (44) and Screw (43) into the 35
Valve Body.
• Do not tighten or seat the Screw. 36
Refer to Figure 2-B
Parts List
26. Lubricate the Primer Rod with grease.
37 for Parts Identification
27. Install the Valve Body assembly onto the upper end of 38
the Primer Rod. 39
• Use a small hammer or other suitable tool. 40
41
28. Tighten the Screw into the Valve Body securely. 42
43
29. Install Guide Washer (42) onto the Primer Rod. 46
44
45
30. Screw Primer Rod (40) into the Adapter and Insert
assembly until the roll pin holes align. 47
27

CAUTION
50
Support the Primer Rod and the Adapter and Insert
assembly during Roll Pin installation. Damage to 48
components can occur. 49

31. Install Roll Pin (39). Figure 5 Pump Tube Assemblies

• Use a small hammer. 323730-A1 and 323730-B1 - Section View

Revision
NSW (8-97) QLD/PNG VIC/TAS 10 WA SA/NT Alemite
NZ Corporation
TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 TEL: (08) 9209 3066 TEL: (08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

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 Parts And Drawing Breakdown For The 7785-A5
High-Pressure Grease Pump SER 7785-A5

32. Install Valve Seat (47), Plate (48), and Stop Nut (49) IMPORTANT: If a primer is used with
onto the Primer Rod. Loctite 222, the curing time is greatly
• Tighten the Stop Nut securely. Place a small punch reduced.
into the hole of the Primer Rod to prevent its rotation
48. Screw Pump Tube (26) onto Adapter (41)
33. Position Adapter (41) horizontally into the vise. [with Loctite 222]. See Figure 2-B.
• Do not tighten.
Internally-Threaded End of Adapter
49. Screw Primer Body (50) [with Loctite 222] into the
34. Install Gasket (27) into the internally-threaded end of
opposite end of the Adapter. See Figure 2-B.
the Adapter.
• Do not tighten.
35. Install the Primer Rod and Piston assembly
(Piston end first) into the Adapter. 50. Screw Jam Nut (22) onto the Pump Tube.
• Center and seat all components properly. Pull on the 51. Push on Plate (48) to expose Coupling (23) from the
Piston as necessary. Use care to ensure the Gasket Pump Tube as necessary.
does not move.

36. Install the additional Gasket (27) onto Valve Seat (47).
Attach Pump Tube to Air Motor
52. Screw the Coupling onto the air motor piston rod until
Externally-Threaded End of Adapter
the Spring Clip holes align.
37. Install Spacer (32) into the externally-threaded end of • Rotate the entire pump tube assembly.
the Adapter.
53. Install the Spring Clip.
• Make sure the Spacer centers and seats properly.

38. Install Gasket (27) into the Adapter. 54. Screw the pump tube assembly into Body (11).

39. Position Barrel assembly (28) with the large diameter 55. Place a large wrench or other suitable tool into the slot
pointing upward. of Primer Body (50).
• Tighten all the components of the assembly securely.
40. Install Wear Ring (29) into the Barrel assembly. Crush all gaskets.

41. Install and seat Seal (30) [lip end first] into the Barrel 56. Tighten Jam Nut (22).
assembly.

42. Install Bearing (31) into the Barrel assembly.

Operation
Bench Test and Prime
CAUTION NOTE: Perform the following procedures at
Use care installing the Barrel assembly over the a pressure not to exceed 40 psi (2.8 Bars).
threads of Piston (33). Damage to the Seal can
occur. 1. Make sure air pressure at the regulator reads zero.

2. Connect a product hose to the pump’s material outlet.

43. Install the Barrel assembly (large diameter first) onto 3. Place the hose into an appropriate collection container.
Piston (33).
• Make sure the Barrel assembly seats properly against 4. Install air Connector (7) to the inlet of the air motor.
Spacer (32).
5. Connect Air Coupler (8) to the Connector.
44. Install Gasket (27) onto the Barrel assembly.
6. Slowly supply air pressure to the pump’s motor.
45. Screw the upper and lower Couplings (23) onto each • The pump assembly should cycle.
end of Pump Tube Rod (25) until the Spring Clip holes
align. If the pump assembly does not cycle, refer to the
Troubleshooting Chart for details.
46. Install Spring Clips (24).

47. Screw the Rod and Coupling assembly onto the Piston.
• Install the Spring Clip.

NSW
Alemite Corporation QLD/PNG
TEL: (02) 9939 0711 TEL: (07) 3204 9166
VIC/TAS
TEL: (03) 8787 8288
11 WA
TEL: (08) 9209 3066
SA/NT
TEL: (08) 8241 7111
NZ
Revision (8-97)
TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

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SER 7785-A5 High-Pressure Grease Pump

Priming Installation
With air pressure at zero: NOTE: The following procedures consider
the pump assembly to be installed onto a
7. Place the pump in the product to be dispensed.
container with a cover.
8. Slowly supply air pressure to the pump’s motor.
1. Install the bolts that attach the cover to the pump
9. Allow the pump to cycle slowly until the system and assembly.
product is free of air. • Tighten the bolts securely.

If the pump assembly does not prime, refer to the 2. Place the follower into the container.
Troubleshooting Chart for details.
3. Press downward and maneuver the follower until
10. Check the motor for air leakage. grease appears around its edges and center hole.
• Make sure all air is removed.
If the motor leaks, refer to the Air Motor Service
Guide for details. 4. Install the pump assembly through the follower and
onto the container.
Stall Test
5. Secure the cover and pump assembly to the container.

Additional items that should be incorporated into the

WARNING air piping systems are listed in Table 5.
Should leakage occur anywhere within the
system, disconnect air to the motor. Personal Part Number Description
injury can occur. 338862 Moisture Separator/Regulator & Gauge Combination

5608-2 Moisture Separator

With air pressure at zero: 7608-B Regulator and Gauge

5908-2 Lubricator *
11. Attach a control valve to the outlet hose of the pump.
Table 5 Air Line Components
12. Set the air pressure to 100 psi (6.9 Bar).
* Although the air motor is lubricated at the factory, the
13. Operate the control valve into a container. life of the motor can be extended with the use of a
lubricator.
14. Allow the pump to cycle until the system and product
is once again free of air.
Alternate Installations
15. Shut off the control valve.
• The pump should not cycle. Pump model 7785-A5 is often mounted:
• from either a single- or dual-post hoist
If the pump cycles slowly (once or twice a minute) or • in bulk grease distribution systems
continuously, refer to the Troubleshooting Chart for
details. When either of these type arrangements are employed,
alternate accessory items must be purchased. See Table 6.

Application Followers Adapter Kit Primer Body

Single-Post Hoist 327242

327247
Dual-Post Hoist 327690

Bulk Grease 333693*

* 1-1/2 " NPTF (m)

Table 6 Accessory Items for Alternate Installations

Revision (8-97) 12 Alemite Corporation

NSW QLD/PNG VIC/TAS WA SA/NT NZ

TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 TEL: (08) 9209 3066 TEL: (08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

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High-Pressure Grease Pump SER 7785-A5

Troubleshooting Chart
d

Pump Indications Possible Problems Solution

Pump does not cycle 1. Air motor not operating properly 1. Inspect air motor and rebuild or
replace as necessary
2. Pump tube jammed and/or contains 2. Rebuild pump tube
loose components
3. Insufficient air pressure 3. Increase air pressure
Pump will not prime 1. Excessive cycling speed 1. Reduce air pressure
2. Pump leaking internally 2. See Internal Leaks
Pump cycles rapidly 1. Product source empty 1. Replenish product
Pump cycles continuously, or 1. Pump leaking internally 1. See Internal Leaks
slowly (once or twice/minute) 2. Pump leaking externally 2. See External Leaks
3. Distribution system leaking 3. Correct leak
External Leaks
Product leakage visible at weep 1. Damaged Seal (17) 1. Separate pump tube from air motor
hole in Body (11) and replace Seal (17)
2. Damaged air motor piston rod. 2. Inspect piston rod and replace as
necessary
Product leakage visible at bottom 1. Pump tube not sufficiently tight 1. Tighten pump tube assembly
of Body (11) 2. Damaged Gasket(s) (20) 2. Separate pump tube from air motor
and replace Gaskets (20)
Air leakage at weep hole in Damaged Seal (15) Separate pump tube from air motor and
Body (11) replace Seal (15)
Product leakage visible at weep 1. Pump tube not sufficiently tight 1. Tighten pump tube assembly
hole in Tube (26) and/or 2. Damaged Gasket(s) (27) 2. Disassemble pump tube and replace
Adapter (41) Gaskets (27)
Internal Leaks
Pump does not prime or cycles 1. Foreign material between Ball (36) and Locate and eliminate source of foreign
continuously, or slowly Adapter and Insert assembly (38) material.
(once or twice/minute) 2. Foreign material between Valve
Body (46) and Valve Seat (47) Disassemble pump tube, clean, inspect
3. Worn or damaged Ball (36) and replace worn or damaged
4. Worn or damaged Adapter and Insert components.
assembly (38)
5. Worn or damaged Valve Body (46)
6. Worn or damaged Valve Seat (47)
7. Worn or damaged Seal (30)
8. Worn or damaged Piston (33)
9. Worn or damaged Seal (45)
10. Worn or damaged Primer Rod (40)

Changes Since Last Printing

Excluded Kit Symbol from Item 35 on Figure 2-B

Alemite Corporation 13 Revision (8-97)

NSW QLD/PNG VIC/TAS WA SA/NT NZ

TEL: (02) 9939 0711 TEL: (07) 3204 9166 TEL: (03) 8787 8288 TEL: (08) 9209 3066 TEL: (08) 8241 7111 TEL: (09) 447 1007
FAX: (02) 9939 0411 FAX: (07) 3204 1224 FAX: (03) 8787 8266 FAX: (08) 9209 3933 FAX: (08) 8241 7011 FAX: (09) 447 1008

Visit our website at www.alemlube.com.au or www.alemlube.co.nz 13