Page 1
OPERAT
OR’S MANUAL
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
66602X–X
RELEASED: 6–10–93
REVISED: 6–21–10
(REV
.H) IPP/PSE
1/4”
DIAPHRAGM PUMP
1:1
RA
TIO (NON–METALLIC)
READ THIS MANUAL CAREFULL
OPERA
THIS MANUAL COVERS THE FOLLOWING MODELS
MODEL TH'D
666023,J,H,L*-XXX
666026,M,N,P*-XXX
* J,H,L,M,N,P Represent Inlet and Outlet Options, refer to page 3 for more information.
TING OR SER
NPT
NPT
SERVICE KITS
Refer to Service Kit Chart on page 3 to match pump material with SerĆ
vice Kits offered. The ``X'' represents a variable digit of the Model No.
637273-XXX for Pump Rebuild. (Model digits 7,8,9)
637274-XX for Check Valve Replacement. (Model digits 7,9)
637275-XX for Diaphragm and Air Section repair. (Model digits 8,9)
637276 for Pre-assembled Replacement Air Valve Section. (Fig.2)
PUMP
DA
TA
Y BEFORE INST
VICING THIS EQUIPMENT
CHECK TYPE
FLAT POLYPROPYLENE
FLAT GROUNDABLE ACETAL
WETTED MATERIAL
ALLING,
.
MODELS - See Model Description Chart for ``-XXX'' on page 3.
PUMP TYPE -Non-Metallic Air Operated Double Diaphragm
MATERIAL - See Model Description Chart on page 3.
WEIGHT LBS. - Polypropylene 3.6 (1.63 kgs)
- Groundable Acetal 4.1 (1.86 kgs)
MAXIMUM AIR INLET PRESSURE - 100 p.s.i.g. (6.9 bar)
MINIMUM AIR INLET PRESSURE - 20 p.s.i.g. (1.4 bar)
MAXIMUM OUTLET PRESSURE - 100 p.s.i.g. (6.9 bar)
MAXIMUM FLOW RATE - 5 g.p.m. (18.9 Liters)
MAXIMUM SUCTION LIFT - 20 Ft. (Water)
MAXIMUM OUTPUT PER CYCLE -.014 Gallons (53 cc's)
MAXIMUM PARTICLE SIZE - 1/32" dia.
MAXIMUM TEMP. LIMITS -
Polypropylene 35_Fto120_F
Groundable Acetal 10_F to 150_F
GROUNDABLE - 666026-XXX Models Only
DIMENSIONAL DATA - See page 8.
NOISE LEVEL*- 59.8 db(A) @ 70 psi, 60 cycles per minute.
* The pump sound pressure levels published here havebeenupdated to an Equivalent Continuous Sound Level (L
GENERAL
The ARO Diaphragm Pump offers high volume delivery even at low air
pressures, easy self priming, the ability to pump various viscosity maĆ
terials and the ability to pass solids (as stated in the chart above). The
pump is designed to correspond to the needs of the user by offering a
variety of wetted parts configurations to handle almost any application.
Refer to the model and option chart on page 3.
DESCRIPTION
666023-XXX
1/4'' DIAPHRAGM PUMP
) to meet the intent of ANSI S1.13-1971, CAGI-PNEUROP S5.1usingfourmicrophonelocations.
Aeq
Model 666026-XXX: The Acetal material used in this pump contains
Stainless Steel fibers, it's conductivity allows it to be connected to a
suitable ground, a ground screw is provided for this.
NOTICE: All possible options are shown in the chart on page 3 however
certain combinations maynot be recommended, consultarepresentative
or the factory if you have questions concerning availability.
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET – BRYAN, OHIO 43506
(800) 495-0276 FAX(800) 892-6276
www.ingersollrandproducts.com
© 2010
Page 2
OPERATING
X
AND SAFETY PRECAUTIONS
Z Read and heed all Warnings, Cautions, and Safety PrecauĆ
tions before operating this pump.
Z Use only genuine ARO replacement parts to assure compatĆ
ible pressure rating and longest service life.
WARNING EXCESSIVE AIR PRESSURE. Can cause pump
damage, personal injury or property damage.
S Do notexceed the maximuminlet air pressureasstated on
the pump model plate.
WARNING STATIC SPARK. Can ignite flammable material
and vapors resulting in fire or explosion causing severe perĆ
sonal injury or property damage.
S The pumping system and object being sprayed must be
grounded when it is pumping, flushing, recirculating or
spraying flammable materials such as paints, solvents,
lacquers, etc. or used in a location where surrounding atĆ
mosphere is conducive to spontaneous combustion.
S 666026-XXX Groundable Acetal pumps: Use the pump
grounding screw provided. A screw terminal is provided
on the Fluid Cap (Remove the cover to gain access). ConĆ
nect a12 ga. (min.)wire (66885-1 Kit is available) to a good
earth ground source.
S Ground dispensing valve or device, containers, hoses
and any object to which material is being pumped.
S After grounding, periodically verify continuity of electrical
path to ground. Test with an ohmmeter from each compoĆ
nent (e.g.,hoses,pump,clamps,container,spray gun, etc.)
to ground to insure continuity. Ohmmeter should show 10
ohms or less.
S Secure pump, connections and all contact points to avoid
vibration and generation of contact or static spark.
S Consult local building codes and electrical codes for speĆ
cific grounding requirements.
WARNING
jury or property damage. Material can be forced out of the air
exhaust muffler.
DIAPHRAGM RUPTURE. Can cause serious inĆ
S Pipe the exhaust to a safe remote location when pumping
hazardous or inflammable materials.
S Use agrounded 1/4" min. I.D. hose between the the pump
and the muffler.
WARNING
injury or property damage. Do not service or clean pump,
hoses or dispensing valve while the system is pressurized.
HAZARDOUS PRESSURE. Can result in serious
S Disconnect air supply line and relieve pressure from the
system by opening dispensing valve or device and/or
carefully and slowly loosening and removing outlet hose
or piping from pump.
WARNING HAZARDOUS MATERIALS. Can cause serious
injury or property damage. Do not attempt to return a pump to
the factoryor service center that containshazardous material.
Safe handling practices must comply with local and national
laws and safety code requirements.
S Obtain Material Safety Data Sheets on all materials from
the supplier for proper handling instructions.
Z SAFETY PRECAUTIONS (GENERAL) should inĆ
clude:
S Use of static wire hoses.
S Submersion of outlet hose end, dispensing valve or deĆ
vice within material being dispensed whenever possible.
(Avoid free streaming of material being dispensed.)
S Proper ventilation of area away from heat, open flames
and sparks.
S Keeping inflammables away from heat, open flames and
sparks.
S Keeping containers closed when not in use.
S Be sure material hoses and other components are able to
withstand fluid pressures developed by this pump. Check
all hoses for damage or wear. Be certain dispensing deĆ
vice is clean and in proper working condition.
CAUTION Verify the chemical compatibility of the pump
wetted parts and the substance being pumped, flushed or reĆ
circulated. Chemical compatibility may change with temperaĆ
ture and concentration of the chemical(s) within the
substances being pumped, flushed or circulated. Consult
ARO FormNo. 8677-P, Fluid Compatibility Guide, for informaĆ
tion on chemical compatibility.
CAUTION
cal stress only. Certain chemicals will significantly reduce
maximum safe operating temperature. Consult Fluid CompatĆ
ibility Guide for chemical compatibility and temperature limĆ
its.
Maximum temperatures are based on mechaniĆ
S Temperature Limits:
Polypropylene 35_Fto120_F
Groundable Acetal 10_Fto150_F.
CAUTION
been trainedfor safe working practices, understand it's limitaĆ
tions, and wear safety goggles/equipment when required.
CAUTION
the piping system. Be certain the system components are
properly supported to prevent stress on the pump parts.
Be certain all operators of this equipment have
Do not use the pump for the structural supportof
S Suction and discharge connections should be flexible
connections (such as hose), not rigid piped, and should
be compatible with the substance being pumped.
CAUTION Prevent unnecessary damage to the pump. Do
not allow pump to operate when out of material for long periĆ
ods of time.
S Disconnect air line from pump when system sits idle for
long periods of time.
WARNING
CAUTION
NOTICE
= Hazards or unsafe practices which could
result in severe personal injury, death or
substantial property damage.
= Hazards or unsafe practices which could
result in minor personal injury, product or
property damage.
= Important installation, operation or
maintenance information.
PAGE 2 OF 8
66602X-
Page 3
MODEL
DESCRIPTION CHART
BASIC MODEL NO.
6660 X X
BODY MATERIAL,
INLET/OUTLET OPTION
23 POLYPROPYLENE, (1)INLET/(1)OUTLET
26 GROUNDABLE ACETAL, (1)INLET/(1)OUTLET
2J POLYPROPYLENE, (1)INLET/(2)OUTLET
2H GROUNDABLE ACETAL, (1)INLET/(2)OUTLET
2L POLYPROPYLENE, (2)INLET/(1)OUTLET
2M GROUNDABLE ACETAL, (2)INLET/(1)OUTLET
2N POLYPROPYLENE, (2)INLET/(2)OUTLET
2P GROUNDABLE ACETAL, (2)INLET/(2)OUTLET
AIR
AND LUBE REQUIREMENTS
WARNING EXCESSIVE AIR PRESSURE. Can cause pump
damage, personal injury or property damage.
– X X X
CHECK VALVE SEAT
MATERIAL
6 ACETAL
S A filter capable of filtering out particles larger than 50 microns
should be used on the air supply. In most applications there is no
lubrication required other than the "O"ring lubricant which is apĆ
plied during assembly or repair.
S The pump can be rotated 360_to suit the application. It may be
mounted upside down or on the wall with no effect on suction lift or
operating efficiency. The filter and regulator need to be oriented in
a normal vertical direction to function properly.
S Pipe plugs included for the material inlets, they can be switched to
accommodate piping requirements however the fluid inlet must alĆ
ways be in the port closest to the mounting base.
S When lubricated air is necessary, supply the air lubricator with a
good grade of SAE 90 wt. non-detergent oil and set the lubricator
to a rate not to exceed one drop per minute.
INSTALLATION
S NOTICE: Re-torque fasteners prior to use. Refer to page step
#22 on page 7 for information.
S Apply tape or pipe sealant to threads upon assembly to preĆ
PTFE
vent leakage.
S Secure the diaphragm pump legs to a suitable surface to insure
against damage by vibration.
S To avoid problems install a particle fluid filter to screen out foreign
matter 1/32'' or larger in diameter.
S The pump is not recommended for submerged applications.
S When the diaphragm pump is used in a forced-feed (flooded inlet)
situation it is recommended that a ``Check Valve''beinstalled at the
air inlet.
FLUID SECTION MATERIAL OPTIONS
FLUID
CHECK
MATERIAL
PTFE
43 POLYPROPYLENE
DIAPHRAGM/O–RING
MATERIAL
.F.E
PTFE/T
4
PTFE/FLOURAZ
D R
E SANTOPRENER/FLUORAZ
S The outlet material volume is governed not only by the air supply
but also by the material supply available at the inlet. The materialĆ
supply tubing should not be too small or restrictive. Be sure not to
use hose which might collapse.
MAINTENANCE
Refer to the part list pg. 4 for Service Kit Information, parts view on
pg. 5. and Repair Proceedures on pgs 6 and 7.
S Certain ARO ``Smart Parts" are indicated which should be availĆ
able for fast repair and reduction of down time.
S Provide a clean work surface to protect sensitive internal moving
parts from contamination from dirt and foreign matter during serĆ
vice disassembly and reassembly.
S Keep good records of service activity and include pump in prevenĆ
tive maintenance program.
SER
VICE KITS
DIAPHRAGM &
66602X- CHECK VALVE
-344 637274-34 637275-44 637273-344
-34D 637274-3D 637275-4D 637273-34D
-34E 637274-3E 637275-4E 637273-34E
-644 637274-64 637275-44 637273-644
-64D 637274-6D 637275-4D 637273-64D
-64E 637274-6E 637275-4E 637273-64E
AIR SECTION REBUILD KIT
OPERATING INSTRUCTIONS
S Always flush the pump with a solvent compatible with the material
being pumped if the material being pumped is subject to ``setting
up" when not in use for a period of time.
S Disconnect the air supply from the pump if it is to be inactive for a
few hours.
66602X-X
S VitonR and HytrelR are registered trademarks of the DuPont Company S KynarR is a registered trademark of Penwalt Corp S FluorazR is a registered trademark of Greene, Tweed & Co. Inc.
S Santoprene R is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. S Key-LubeRis a registered trademark of Key Industries
PAGE 3 OF 8
Page 4
X
PARTS
SERVICE KITS
CHECK VALVE KIT
DIAPHRAGM & AIR VALVE KIT
COMPLETE REBUILD KIT
AIR VALVE REPLACEMENT ASM.
LIST
637274-XX
637275-XX
637273-XXX
637276
Refer to the Kit Selection Chart page 3 for proper ``-XXX" for your model.
THESE ITEMSARE INCLUDED IN THE KITSKIT NUMBER
19 33
719336471102 119 137 138 144 146 147
7 19 33 64 71 102 110 119 137 138 144 146 147
110
102 137 146 147
132
132
132
DIAPHRAGM OPTIONS
``7" ``64" ``19" ``33"
66602X
-XXX
-XX4 H93898 [T] H93947 [B] H93831 [T] H93830 [T]
-XXD H93898 [T] H93947 [B] H93933 [F] H93932 [F]
-XXE H93808 [SP] --- -- H93933 [F] H93932 [F]
DIAPHRAGM
(2)
[MTL]
``O"ring (2)
79mm X 4 mm
[MTL]
``O"ring (8)
1-1/8" O.D.
[MTL]
``O"ring (4)
3/4" O.D.
COMMON PARTS
POLYPROPYLENE GROUNDABLE
666023,J,L,N 666026,H,M,P
ITEM DESCRIPTION (SIZE IN INCHES) QTY PART NO. [MTL] PART NO. [MTL]
j1 Rod (2-13/16 Long) (1) 93916 [S] 93916 [S]
j5 Washer (1-3/4 O.D.) (2) 93915 [SS] 93915 [SS]
j6 Diaphragm Nut (1/4-20) (2) 93810-1 [P] 93810-2 [D]
j16 Manifold (4) 93817-1 [P] 93817-2 [G]
j36 Manifold Tube (`) 93813-1 [P] 93813-2 [D]
37 Manifold Plug (`) 93941-1 [P] 93941-2 [D]
43 Ground Screw (10-32 x 1/4) Not Shown (1) ----- -- 93005 [S]
62 Nut (1/4-20) (6) 93828 [SS] 93828 [SS]
63 Pipe Plug (1/4-18) Not Shown (2) 93832-1 [P] 93832-2 [D]
j65 Fluid Cap, W/AIR INLET (1) 93812-1 [P] 93812-2 [G]
j66 Fluid Cap (1) 93811-1 [P] 93811-2 [G]
j68 Air Cap, Right (w / Groove d ) (1) 93804 [P] 93804 [P]
j69 Air Cap, Left (w / Tongue Z ) (1) 93805 [P] 93805 [P]
71 Check Asm.: Seat, Disc, Stop (4) H66973-1 [P] H66973-2 [D]
72 Cover, Right (1) 93816-2 [P] 93816-2 [P]
73 Cover, Left (1) 93816-1 [P] 93816-1 [P]
131 Bolt (1/4-20 x 6.250) (6) 93827 [SS] 93827 [SS]
145135111 118
142
[MTL]
MATERIAL
[A]=Aluminum
[B]=Buna ``N''
[D]=Acetal (Orange*)
[F]=Fluoraz
[G]=Groundable Acetal (Dk Gray)
[K]=Kraton
[N]=Neoprene
[P]=Polypropylene (Lt Gray)
[R]=Ryton
[S]=Steel
[SP]=Santoprene
[SS]=Stainless Steel
[T]= PTFE
[U]=Polyurethane
*Refers to wetted parts only
PART NOTES
` Manifold Qty's will be either
1 or 2 depending on the inlet/outlet
option selected. (Refer to to chart
on page 3.)
H These parts are available in
Service Kits only, see the Service
Kit Chart at the top of the page and
on page 3.
V ``Smart Parts'' keep these items
on hand in addition to the Service
Kits for fast repair and reduction of
down time.
CODE
Keylube packet
93706-1 is
included
with all kits.
AIR SECTION PARTS
ITEM DESCRIPTION (Size in Inches)
QTY
PART NO. [MTL] ITEM DESCRIPTION (Size In Inches)
102 ``O''Ring (7/8 O.D.) (3) HY325-018 [B] 137 ``O''Ring (1 O.D.) (1) HY325-020 [B]
103 Bushing (1) 93917 [D] 138 ``O''Ring (13/16 O.D.) (1) HY325-114 [B]
110 ``U''Cup (13/16 O.D.) (1) HY186-54 [B] 142 Screw (#4-20) (3) 93942 [SS]
j111 Spool Asm.-(Incl'ds #110,#119,#138) (1) 65438 [D] 144 ``U''Cup (5/8 O.D.) (2) HY186-45 [B]
j118 Trip Rod Asm.- Inculdes (4) #119 (1) 65439 [D] j145 Minor Valve Block (1) 93807 [R]
119 ``O''Ring (5/8 O.D.) (1) H15066 [B] 146 ``O''Ring (5/16 O.D.) (2) HY325-008 [B]
132 Gasket (1) H93809 [K] 147 ``O''Ring (7/16 O.D.) (2) HY325-011 [B]
j135 Valve Block (1) 93806 [R]
PAGE 4 OF 8
QTY
PART NO. [MTL]
66602X-
Page 5
PARTS
LIST
73
62 ,
16
68
71
19
66
6 ,
147
144
144
103
64
69
1
5
,
7
Z
33
72
``B''
33
65
d
Logo
Plate
These parts are included in Air Valve Replacement Kit 637276.
135
102
137
111
119
110
138
146
119
145
102
118
FIGURE 2
AIR VALVE
(SHOWN
2X SCALE)
132
142,
146
102
FIGURE 1
``A''
INLET /
OUTLET
OPTIONS
SI/SO
SI/DO
DI/SO
DI/DO
MANIFOLD TUBE
``A''
131 ,
``B''
36
36
36
37
37
36
37
37
. TORQUE REQUIREMENTS ,
NOTE: DO NOT OVERTIGHTEN FASTENERS
(6) / (5) Diaphragm nut / washer 75-85 in.lbs.
use Loctite #242, tighten together.
(62) / (131) Manifold bolts / nuts 35-45 in.lbs.,
tighten together alternately & evenly, then re-torque.
(142) Torque to 4-6 in.lbs.
LUBRICATION
Apply Keylube (93706-1) to all
``O"rings, ``U''Cups & mating parts
66602X-X
PAGE 5 OF 8
Page 6
X
PUMP
DISASSEMBL
Y AND REASSEMBL
Y
GENERAL PUMP REPAIR NOTES:
S Tools needed to complete disassembly and repair.:
S 7/16" Wrench, 9/16" Wrench,7/16" Socket, 9/16" Socket,
Spanner Wrench, Torque Wrench (measuring inch pounds),
``O"ring Pick.
S Once the pump is disassembled, you have the opportunity to clean
and inspect all parts for wear. Look for deep scratches on metallic
surfaces, and nicks or cuts in ``O"rings. Replace old parts with new
ones as necessary.
S Take precautions to prevent cutting ``O"rings upon installation.
S Lubricate ``O"rings and ``U''cups with Key-lube or equivalent. A
packet of this lubricant is included in each Service Kit.
S Do not over-tighten fasteners, refer to torque specification block
on view.
S Re-torque fasteners following restart.
Service Kits available. From your local distributor.
(Kits also include Keylube grease packet.)
S SERVICE KIT: 637273-XXX contains parts for a complete pump
rebuild.
S SERVICE KIT: 637274-XX contains new check assemblies.
S SERVICE KIT: 637275-XX includes parts to rebuild the air motor
and diaphragms.
S AIR VALVE REPLACEMENT KIT: 637276 includes a complete
factory pre-assembled replacement air valve section.
PUMP DISASSEMBLY:
1. Place the pump on a flat workbench. Remove both cover plates
and set them aside.
2. Using a 7/16-inch wrench, loosen the bolts that run through the
pump and remove the six nuts. Pull the bolts through the pump
body and set them aside.
3. The fluid caps and manifolds may fall free at this time. If not, grasp
the fluid caps and separate them from the pump body.
4. The air inlet fluid cap has two small ``O"rings at the air inlet and exĆ
haust ports. Remove these with the ``O"ring pick.
5. The manifold tubes may have pulled free of the pump when the
fluid caps were removed, if not remove both tubes from the pump
body.
6. Remove the ``O"rings from the ends of each manifold tube.
7. If the manifolds did not fall free, separate them from the fluid caps
at this time.
8. To remove the checks, it may be necessary to push a dowel
through the fluid caps.
9. Use the pick to remove any ``O"rings that remain in the manifold or
fluid cap.
10. With the 9/16" socket and 9/16" wrench, loosen and remove either
diaphragm nut. Gently pull the diaphragm away from the pump
body.
NOTE: Models with diaphragms will have back up ``O"rings.
11. Push the connecting rod through the pump body. Wrap the conĆ
necting rod in a shop rag and secure in a soft-jawed vise.
12. Remove the remaining diaphragm nut with a 9/16-inch wrench.
NOTE: Be careful not to mar the connecting rod surface during this
step.
13. Using the 9/16" wrench and the spanner wrench, remove the backĆ
up washer from the diaphragm nut. This will allow you to separate
PTFE
the diaphragm from the nut.
NOTE: Be careful not to round the diaphragm nut during this step.
14. Pull apart the two air caps. The connecting rod bushing will fall free.
If the air valve block asm. did not fall free, pull it from the air cap at
this time.
15. Use the ``O"ring pick to remove the air cap seal.
16. Use the pick to remove the U-cups and any ``O"rings that may reĆ
main in the air caps.
17. Remove the retaining screws and separate the valve block and miĆ
nor valve block. Pull the piston from the minor valve block. Then
remove all ``O"rings using the pick. Gently push the spool from the
valve block. A dowel may be needed to push out the spool.
NOTE: Be careful not to damage either part during this step.
18. Use the pick to remove all ``O"rings from the spool and the center
gasket from the valve block.
PUMP REBUILD PROCEDURES: (rebuild by service kits)
For the 637273-XXX and 637275-XX Service Kits
AIR VALVE SECTION (Steps 1-6)
1. Install new ``O"rings and U-cup on the spool and piston.
2. Lubricate the spool, piston and internal bores of the valve blocks.
3. Insert the piston into the minor valve block, being careful not to
damage any ``O"rings during this process. Now slide the spool into
the valve block, inserting the small end first.
NOTE: There may be some resistance when installing the piston
and spool, however you should not have to force the parts into
place.
4. Install the shaped gasket into the minor valve block and push the
major valve block into the minor valve block, retain with screws and
torque to 6 in.lbs.
NOTE: Do not lubricate the gasket or valve block surfaces.
5. Insert new, lubricated ``U''cups in each of the air caps. The lips of
the ``U''cups should face towards the diaphragm chambers. Install
the air cap seal.
6. Pre-assemble each of the two diaphragms by first inserting the diĆ
aphragm nut through the new diaphragms, Appy Loctite #242 to
the threads, attach the backup washer, secure with the a 9/16"
wrench and spanner wrench. Using a torque wrench, tighten the
diaphragm nut and washer to 80-inch pounds.
NOTE: Be careful not to round off the diaphragm nut. Backup
``O"rings are included in the Service Kit for models with diaĆ
phragms.
For the 637274-X and 637273-XXX Service Kits:
7. Install new, lubricated ``O"rings onto the four complete check asĆ
semblies that are included with the Service Kit. Also put new
``O"rings on each end of the two manifold tubes.
PUMP REASSEMBLY:
8. First hand tighten the connecting rod to one of the diaphragm asĆ
semblies.
9. Place the air cap on end. Insert the air valve assembly and bushing
in place. (be sure the U-cups are installed). Align logo plates and
push the air caps together.
NOTE: Be sure the bushing, and air valve assembly remain in
place.
10. Lubricate the connecting rod and insert it into the air cap.
NOTE: Models with diaphragms have backup ``O''rings that
are placed in the groove of each air cap.
PTFE
PTFE
PAGE 6 OF 8
66602X-
Page 7
REASSEMBLY (CONT’D)
11. Attach the second diaphragm assembly to the connecting rod,
hand tighten the (pre-assembled) diaphragm nut and washer until
it bottoms out on the connecting rod.
NOTE: Models with Teflon diaphragms have backup ``O"rings that
are placed in the groove of each air cap. Do not over-tighten the
nut.
12. Replace the ``O"rings at the air inlet and exhaust ports of the air inĆ
let fluid cap.
13. Properly align the fluid cap and attach it to the pump body. When in
place, the air inlet should be at the upper right, with the exhaust at
the lower left.
14. Insert a bolt into the bore just below the air inlet and one just above
the exhaust port. Applying a small amount of anti-seize compound
or lubricant to the threads will help prevent the nut from binding.
Properly align the second fluid cap and push it into position.
15. Secure the fluid caps by installing nuts onto each bolts, but do not
tighten fully at this time.
16. Insert the manifold tubes through the pump body, being careful that
the ``O"rings do not fall off during this step.
17. Press two of the check assemblies into the lower inlet ports of the
fluid caps. The checks are keyed and can be assembled only one
way.
NOTE: If the old checks are to be used, clean all parts in an apĆ
propriate solvent.
18. Place manifolds over each check, pushing firmly to secure the
check and the manifold tube.
19. Press the remaining checks into the upper, outlet ports of the fluid
caps. Make sure the smaller seat opening is inserted first.
20. Place manifolds over each check, pushing firmly to secure the
check and the manifold tube.
21. Insert two bolts through each manifold. Secure by attaching a nut
to each bolt. Applying a small amount of anti-seize compound or
lubricant to the threads will help prevent the nut from binding.
22. Tightening sequence for the long bolts:
IMPORTANT ASSEMBLY NOTE: The fastener nuts have ribs
which lock into the material, for best results place a socket wrench
on the nuts so they are held stationary and tighten only the bolts
they are used with.
. Torque all six bolts to 40-inch pounds.
. Cross tighten the bolts in an alternating star shaped
pattern.
. Repeat torque sequence twice.
23. Finish reassembly by pressing both cover plates into place.
TROUBLE SHOOTING
Air Motor stalls
S Check for blown Diaphragm
S Check for damaged ``O"rings on the Spool.
S Check for damaged ``O"rings on the Trip Rod.
S Check valve block gasket for leakage.
Air leaks from Exhaust
S Check for damaged ``O"rings on the Valve Block and Minor Valve
Block, Spool or Trip Rod.
S Check gasket between valve blocks for leakage.
S U-cups on Connecting Rod Bushing are damaged or installed
backwards.
Fluid leaks from Exhaust
S Check for diaphragm damage.
S Check for diaphragm screws not adequately torqued.
Low flow, or pump continues to cycle after shut-off.
S Check for trapped air if the pump is oriented where the inlet check
is above the outlet check. Temporarily increase the flow or reprime the pump.
S Check for damaged seats or foreign matter clogging the check asĆ
sembly.
Air leaks from pump (other than exhaust)
S Check for bolts not evenly or adequately torqued.
S Check for ``O"ring missing/damage between the fluid cap and the
air cap on the air inlet side.
External fluid leaks from pump.
S Check for bolts not properly torqued.
S Check for damaged ``O"rings on the Manifold Tube.
S Check for damaged ``O"rings on the Valve Check.
S Check for damaged diaphragm seal.
Pump operates but dispenses little or no fluid
S Check for obstruction in fluid line.
S Check for foreign matter clogging check assemblies.
Note: Install a fluid screen on the material inlet hose if the problem
continues.
S Suction line too small.
S Check for air leakage at the air/fluid inlet pipe plugs. Use
tape or pipe sealant upon assembly.
PTFE
66602X-X
PAGE 7 OF 8
Page 8
DIMENSIONAL
X
Dimensions shown are for reference only, they are shown in inches and millimeters (mm).
DA
TA
4-1/2
(114 mm)
1-3/8
(35 mm)
11/16
(18 mm)
4-3/4
(121 mm)
5-1/2
(140 mm)
1-13/16
(46 mm)
END VIEWS
11/16
(18 mm)
4-3/8
(113 mm)
1-1/4
(32 mm)
5/16 SLOT
(8 mm)
SIDE VIEW
5-5/8
(142 mm)
6-1/2
(165 mm)
7-3/8
(188 mm)
PAGE 8 OF 8
PN 97999-571
66602X-
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