Page 1
OPERATOR’S MANUAL PD03P-XXX-XXX
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
3/8” DIAPHRAGM PUMP
1:1 RATIO, NON-METALLIC
READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.
It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference.
SERVICE KITS
Refer to Model Description Chart to match the pump material options.
637428 for air section repair (see page 6).
637429-XX for uid section repair (see page 4)
PUMP DATA
Models . . . . . . see Model Description Chart for “-XXX”.
Pump Type . . . Air Operated Double Diaphragm.
Material . . . . . see Model Description Chart.
Weight. . . . . . . . PD03P-XDS-XXX. . . . . . . 4.16 lbs (1.89 kgs)
PD03P-XES-XXX. . . . . . . . 4.26 lbs (1.93 kgs)
PD03P-XKS-XXX . . . . . . . 4.50 lbs (2.04 kgs)
PD03P-XLS-XXX . . . . . . . 4.62 lbs (2.10 kgs)
PD03P-XPS-XXX . . . . . . . 3.44 lbs (1.56 kgs)
PD03P-XRS-XXX . . . . . . . 3.50 lbs (1.59 kgs)
Maximum Air Inlet Pressure . . . . . . . . 100 p.s.i.g. (6.9 bar)
Maximum Material Inlet Pressure . . . 10 p.s.i.g. (0.69 bar)
Maximum Outlet Pressure . . . . . . . . . . 100 p.s.i.g. (6.9 bar)
Air Consumption @ 40 p.s.i.g. . . . . . . .
Maximum Flow Rate
ball check. . . . . . . . . . . 10.6 g.p.m. (40.1 l.p.m.)
duckbill . . . . . . . . . . . . . 8.7 g.p.m. (32.9 l.p.m.)
Displacement / Cycle @ 100 p.s.i.g
Maximum Particle Size
ball check. . . . . . . . . .
Maximum Temperature Limits (diaphragm / ball / seal material)
Acetal . . . . . . . . . . . . . . . . . . . . . . -10 to 180 F (-12 to 82 C)
E.P.R / EPDM . . . . . . . . . . . . . . . .
Hytrel . . . . . . . . . . . . . . . . . . . . . -20 to 150 F (-29º to 66 C)
Kynar P.V.D.F . . . . . . . . . . . . . . 10
Neoprene. . . . . . . . . . . . . . . . . . . 0
Nitrile . . . . . . . . . . . . . . . . . . . . . . 10
Polypropylene . . . . . . . . . . . . . . 35
Santoprene . . . . . . . . . . . . . . . -40 to 225 F (-40 to 107 C)
PTFE . . . . . . . . . . . . . . . . . . . . . . 40
. . . . . . . . . . . . . . . . . . . . . -40 to 350 F (-40 to 177 C)
Viton
Groundable Models . . . . . . . . . PD03P-XDS-XXX
PD03P-XES-XXX
Dimensional Data . . . . . . . . . . . . . . . . see page 8
Noise Level @ 70 p.s.i., 60 c.p.m. . . . . . 72.7 db(A)
The pump sound pressure levels published here have been updated to an Equivalent
Continuous Sound Level (L
ROP S5.1 using four microphone locations.
NOTICE: All possible options are shown in the chart, however, certain combinations may not be recommended, consult a representative or the factory if you have questions concerning availability.
( ooded inlet)
ball check. . . . . . . . . . 0.022 gallons (0.083 lit.)
duckbill . . . . . . . . . . . . . 0.018 gallons (0.068 lit.)
duckbill. . . . . . . . . . . . .
-60 to 280 F (-51 to 138 C)
to 200 F (-18º to 93 C)
) to meet the intent of ANSI S1.13-1971, CAGI-PNEU-
Aeq
.
1 c.f.m /gallon (approx.)
1/16” dia. (1.6 mm)
bers)
to 200 F (-12º to 93 C)
to 180 F (-12º to 82 C)
to 175 F (2 to 79 C)
to 225 F (4 to 107 C)
MODEL DESCRIPTION CHART
PD03
Center Section Material
P - Polypropylene
Fluid Connection
A - 3/8 - 18 N.P.T.F. - 1
B - Rp 3/8 (3/8 - 19 BSP)
Fluid Caps / Manifold Materia
D - Groundable Acetal (single port)
E - Groundable Acetal (multiple port)
K - Kynar PVDF (single port)
L - Kynar PVDF (multiple port)
P - Polypropylene (single port)
R - Polypropylene (multiple port)
Hardware Material
S - Stainless Steel
Seat Materia
D - Acetal S - Stainless Steel
K - Kynar PVDF 0 - (Duckbill)
P - Polypropylene
Ball Material (*) Duckbill models
A - Santoprene
C - Hytrel
J - Nitrile (*)
N - Neoprene (*)
Diaphragm Material
A - Santoprene T - PTFE / Santoprene
C - Hytrel V - Viton
FLUID SECTION SERVICE KIT SELECTION
Example: Model # PD03P-ARS-SAA
Fluid Section Service Kit # 637429-AA
l
l
S - Stainless Steel
T - PTFE
V - Viton
K - EPR (*)
L - Viton (*)
RELEASED: 12-17-05
REVISED:
F)
(REV.
P-X X S-X
PD03P - ARS - S X X
637429 - X X
DiaphragmBall
6-25-13
Figure 1
XX
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET – BRYAN, OHIO 43506
(800) 495-0276 FAX(800) 892-6276
www.ingersollrandproducts.com
© 2013 CCN 15255995
Page 2
OPERATING AND SAFETY PRECAUTIONS
READ, UNDERSTAND, AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.
Obtain Material Safety Data Sheets on all materials
EXCESSIVE AIR PRESSURE
S TATIC SPARK
WARNING
EXCESSIVE AIR PRESSURE. Can cause per-
HAZARDOUS MATERIALS
HAZARDOUS PRESSURE
sonal injury, pump damage or property damage.
Do not exceed the maximum inlet air pressure as
y
stated on the pump model plate.
Be sure material hoses and other components are able
y
to withstand fluid pressures developed by this pump.
Check all hoses for damage or wear. Be certain dispensing device is clean and in proper working condition.
WARNING
STATIC SPARK. Can cause explosion
resulting in severe injury or death. Ground pump and
pumping system.
PD03P-XDS-XXX and PD03P-XES-XXX Groundable
y
Acetal pumps: Use the pump ground lug provided.
Connect to a 12 ga. (minimum) wire (kit is included) to
a good earth ground source.
Sparks can ignite ammable material and vapors.
y
The pumping system and object being sprayed must be
y
grounded when it is pumping, ushing, recirculating or
spraying ammable materials such as paints, solvents,
lacquers, etc. or used in a location where surrounding
atmosphere is conducive to spontaneous combustion.
Ground the dispensing valve or device, containers, hoses and any object to which material is being pumped.
Secure pump, connections and all contact points to
y
avoid vibration and generation of contact or static spark.
Consult local building codes and electrical codes for
y
speci c grounding requirements.
After grounding, periodically verify continuity of
y
electrical path to ground. Test with an ohmmeter
from each component (e.g., hoses, pump, clamps, container, spray gun, etc.) to ground to insure continuity.
Ohmmeter should show 0.1 ohms or less.
Submerse the outlet hose end, dispensing valve or
y
device in the material being dispensed if possible.
(Avoid free streaming of material being dispensed.)
Use hoses incorporating a static wire.
y
Use proper ventilation.
y
Keep in ammables away from heat, open ames and
y
sparks.
Keep containers closed when not in use.
y
WARNING
Pump exhaust may contain contaminants.
Can cause severe injury. Pipe exhaust away from work
area and personnel.
In the event of a diaphragm rupture, material can be
y
forced out of the air exhaust mu er.
Pipe the exhaust to a safe remote location when
y
pumping hazardous or in ammable materials.
Use a grounded 3/8” minimum i.d. hose between the
y
pump and the mu er.
WARNING
HAZARDOUS PRESSURE. Can result in
serious injury or property damage. Do not service
or clean pump, hoses or dispensing valve while the
system is pressurized.
Disconnect air supply line and relieve pressure from
y
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 factory or service center that contains
hazardous material. Safe handling practices must comply
with local and national laws and safety code requirements.
y
from the supplier for proper handling instructions.
WARNING
aluminum wetted parts cannot be used with
1,1,1-trichloroethane, methylene chloride or other
halogenated hydrocarbon solvents which may react
and explode.
Check pump motor section, uid caps, manifolds and
y
all wetted parts to assure compatibility before using
with solvents of this type.
CAUTION
pump wetted parts and the substance being pumped,
flushed or recirculated. Chemical compatibility may
change with temperature and concentration of the
chemical(s) within the substances being pumped,
ushed or circulated. For speci c uid compatibility,
consult the chemical manufacturer.
CAUTION
on mechanical stress only. Certain chemicals will
significantly reduce maximum safe operating
temperature. Consult the chemical manufacturer for
chemical compatibility and temperature limits. Refer
to PUMP DATA on page 1 of this manual.
CAUTION
have been trained for safe working practices,
understand it’s limitations, and wear safety goggles /
equipment when required.
CAUTION
support of the piping system. Be certain the system
components are properly supported to prevent stress
on the pump parts.
Suction and discharge connections should be exible
y
connections (such as hose), not rigid piped, and should
be compatible with the substance being pumped.
CAUTION
pump. Do not allow pump to operate when out of
material for long periods of time.
Disconnect air line from pump when system sits idle
y
for long periods of time.
CAUTION
assure compatible pressure rating and longest service life.
NOTICE
pump may not prime properly if the balls do not check by
gravity upon start-up.
NOTICE
OPERATION.
cause fasteners to loosen. Re-torque all fasteners to insure
against uid or air leakage.
NOTICE
upon request: Static Spark” pn \ 93616-1, Diaphragm
Rupture” pn \ 93122.
WARNING
CAUTION
NOTICE
EXPLOSION HAZARD. Models containing
Verify the chemical compatibility of the
Maximum temperatures are based
Be certain all operators of this equipment
Do not use the pump for the structural
Prevent unnecessary damage to the
Use only genuine ARO® replacement parts to
Install the pump in the vertical position. The
RE-TORQUE ALL FASTENERS BEFORE
Creep of housing and gasket materials may
Replacement warning labels are available
=
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 12 PD03P-XXX-XXX (en)
Page 3
GENERAL DESCRIPTION
The ARO diaphragm pump offers high volume delivery even
at low air pressure and a broad range of material compatibility
options available. Refer to the model and option chart. ARO
pumps feature stall resistant design, modular air motor / uid
sections.
Air operated double diaphragm pumps utilize a pressure differential in the air chambers to alternately create suction and
positive uid pressure in the uid chambers, ball checks insure
a positive ow of uid.
Pump cycling will begin as air pressure is applied and it will
continue to pump and keep up with the demand. It will build
and maintain line pressure and will stop cycling once maximum line pressure is reached (dispensing device closed) and
will resume pumping as needed.
AIR AND LUBE REQUIREMENTS
WARNING
damage, personal injury or property damage.
A filter capable of filtering out particles larger than 50
y
microns should be used on the air supply.
brication required other than the “O” ring lubricant which is
applied during assembly or repair.
If lubricated air is present, make sure that it is compatible
y
with the “O” rings and seals in the air motor section of
the pump.
EXCESSIVE AIR PRESSURE. Can cause pump
There is no lu-
OPERATING INSTRUCTIONS
Always flush the pump with a solvent compatible with
y
the material being pumped if the material being pumped
is subject to “setting up” when not in use for a period of
time.
Disconnect the air supply from the pump if it is to be in-
y
active for a few hours.
The outlet material volume is governed not only by the
y
air supply but also by the material supply available at the
inlet. The material supply tubing should not be too small
or restrictive. Be sure not to use hose which might collapse.
When the diaphragm pump is used in a forced-feed
y
( ooded inlet) situation, it is recommended that a Check
Valve” be installed at the air inlet.
Secure the diaphragm pump legs to a suitable surface to
y
insure against damage by vibration.
MAINTENANCE
Certain ARO “Smart Parts” are indicated which should be
y
available for fast repair and reduction of down time.
Provide a clean work surface to protect sensitive internal
y
moving parts from contamination from dirt and foreign
matter during service disassembly and reassembly.
Keep good records of service activity and include pump
y
in preventive maintenance program.
Service Kits are available to service two separate Dia-
y
phragm Pump functions: 1. AIR SECTION, 2. FLUID SECTION. The Fluid Section is divided further to match typical
active MATERIAL OPTIONS.
TYPICAL CROSS SECTION
Figure 2
Santoprene
is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. Lubriplate® is a registered trademark of Lubriplate Division (Fiske Brothers Re ning Company)
®
PD03P-XXX-XXX (en) Page 3 of 12
Viton®and Hytrel® are registered trademarks of the DuPont® Company Loctite® is a registered trademark of Henkel Loctite Corporation
Page 4
y
637429-XX Fluid Section service kits include: Balls (see BALL OPTION, refer to -XX in chart below), Diaphragms (See DIAPHRAGM
n
PARTS LIST / PD03P-XXX-XXX FLUID SECTION
OPTION, refer to -XX in chart below) and item 19 (listed below), plus items 144, 174 and 94276 Lubriplate® grease (page 6).
SEAT OPTIONS
PD03P-XXS-XXX
“21”
-XXX Seat Qty [Mtl] -XXX Ball Qty [Mtl] -XXX Duckbill Qty [Mtl]
-DXX 96580-2 (4) [D] -XAX 96481-A (4) [Sp] -XJX 96744-2 (4) [B]
-KXX 96580-3 (4) [K] -XCX 96481-C (4) [H] -XNX 96744-3 (4) [N]
-PXX 96580-1 (4) [P] -XSX 96513 (4) [SS] -XLX 96744-4 (4) [V]
-SXX 96537 (4) [SS] -XTX 96481-4 (4) [T] -XKX 96744-1 (4) [E]
-0XX 96745 (4) [P] -XVX 96481-3 (4) [V]
NOTE: Item 19 “O” ring is not used with PD03P-XXX-0XX seat option.
n
BALL / DUCKBILL OPTIONS
PD03P-XXS-XXX
“22” (5/8” dia.)
MATERIAL CODE
[A] = Aluminum
[B] = Nitrile
42”
n
[D] = Acetal
[E] = E.P.R.
[GA] = Groundable Acetal
[GFN] = Glass Filled Nylon
[H] = Hytrel
[K] = Kynar PVDF
[N] = Neoprene
[P] = Polypropylene
[PPG] = Glass Filled
Polypropylene
[Sp] = Santoprene
[SS] = Stainless Steel
[T] = PTFE
[V] = Viton
DIAPHRAGM OPTIONS PD03P-XXS-XXX
n SERVICE KIT
-XX = (Ball) “O” Ring
-XXX -XX = (Diaphragm)
-XXA 637429-XA
-XXC 637429-XC 96533-C (2) [H] ----- --- --- Y325-119 (4) [B]
-XXT 637429-XT 96538 (2) [T] 96533-A (2) [Sp] 96514 (4) [T]
-XXV 637429-XV 96558 (2) [V] ----- --- --- Y327-119 (4) [V]
Diaphragm Qty [Mtl] Diaphragm Qty [Mtl]
96533-A (2) [Sp] ----- --- --- 93761 (4) [E]
“7”
n
“8”
n
(3/32” x 1-1/8” o.d.)
n
“19”
Qty [Mtl]
MANIFOLD / FLUID CAP OPTIONS PD03P-XXS-XXX
Polypropylene Kynar PVDF Groundable Acetal
PD03P-XPS- PD03P-XRS- PD03P-XKS- PD03P-XLS- PD03P-XDS- PD03P-XES
Item Description
6 Diaphragm Nut
15 Fluid Cap (2) 96460-1 [P] 96460-1 [P] 96460-3 [K] 96460-3 [K] 96460-2 [GA] 96460-2 [GA]
43 Ground Strap (1) ----- --- ----- --- ----- --- ----- --- 92956-1 [SS] 92956-1 [SS]
Ground Kit Assembly
57
(not shown)
60 Inlet Manifold
61 Outlet Manifold
63 Pipe Plug
(size)
(N.P.T.F.)
(BSP)
(N.P.T.F.)
(BSP)
Qty
Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl]
(1/4” - 20)
93810-7 [P] 93810-7 [P] 93810-3 [K] 93810-3 [K] 93810-2 [D] 93810-2 [D]
(2)
(1) ----- --- ----- --- ----- --- ----- --- 66885-1 66885-1
(1) 96468-1 [P] 96468-7 [P] 96468-3 [K] 96468-9 [K] 96468-2 [GA] 96468-8 [GA]
(1) 96468-4 [P] 96468-10 [P] 96468-6 [K] 96468-12 [K] 96468-5 [GA] 96468-11 [GA]
(N.P.T.F.)
(1) 96469-1 [P] 96469-1 [P] 96469-3 [K] 96469-3 [K] 96469-2 [GA] 96469-2 [GA]
(BSP)
(1) 96469-4 [P] 96469-4 [P] 96469-6 [K] 96469-6 [K] 96469-5 [GA] 96469-5 [GA]
(1) ----- --- 94478-1
(1) ----- --- 96559-1
[PPG]
----- --- 94478-3 [K] ----- --- 94478-2 [D]
[PPG]
----- --- 96559-3 [K] ----- --- 96559-2 [D]
COMMON PARTS
Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]
29
(1/4” - 20 x 1-1/8”)
(1/4” - 20)
Nut
(12) 96471 [SS]
(20) 93828 [SS]
1 Connecting Rod (1) 96532 [SS] 27 Bolt
o
5 Diaphragm Washer (2) 96556 [GFN]
26 Bolt
(1/4” - 20 x 1-1/8”)
(8) 96471 [SS] 77 Logo Plate (2) 93264 [A]
DUAL INLET / DUAL OUTLET KITS 637442-X
Polypropylene Kynar PVDF Groundable Acetal
637442-1 (N.P.T.) 637442-4 (BSP) 637442-3 (N.P.T.) 637442-6 (BSP) 637442-2 (N.P.T.) 637442-5 (BSP)
Item Description
(size)
17 Dual Outlet Manifold (2)
18 Dual Inlet Manifold (2) 96519-1 [P] 96519-4 [P] 96519-3 [K] 96519-6 [K] 96519-2 [GA] 96519-5 [GA]
19 O” Ring
Smart Parts” keep these items on hand in addition to the service kits for fast repair and reduction of down time.
o
Page 4 of 12 PD03P-XXX-XXX (en)
(3/32” x 1-1/8” o.d.)
Qty
Part No. [Mtl]
96520-1 [P]
Part No. [Mtl]
96520-4 [P]
Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl]
96520-3 [K] 96520-6 [K] 96520-2 [GA] 96520-5 [GA]
(1) 96514 [T] 96514 [T] 96514 [T] 96514 [T] 96514 [T] 96514 [T]
Page 5
PARTS LIST / PD03P-XXX-XXX FLUID SECTION
COLOR CODE
MATERIAL COLOR COLOR
Hytrel Cream Black (
Santoprene Tan Tan
Viton Yellow (
DIAPHRAGM BALL
17
61
AIR MOTOR SECTION
29
43
71
42
21
) Yellow (
( ) Dot
FOR THE
SEE PAGES 6 & 7
3
)
5
)
2
1
6
4
Torque Sequence
22
21
19
26
29
5 27 6
63
60 (PD03P-XES-XXX,
PD03P-XL
PD03P-XR
29
60 (PD03P-XDS-XXX,
PD03P-XK
PD03P-XP
18
ASSEMBLY TORQUE REQUIREMENTS
(6) diaphragm nut, 60 - 70 in. lbs (6.8 - 7.9 Nm).
(29) nut, 50 - 60 in. lbs (5.6 - 6.8 Nm), / alternately and evenly, then re-torque after initial run-in.
NOTE: DO NOT OVERTIGHTEN FASTENERS.
42
21
S-XXX,
S-XXX)
S-XXX,
S-XXX)
Figure 3
77
15
26
22
21
19
Stainless steel seat installation
Radius
(ball side)
Chamfer
(uid inlet side)
View for PD03P-XXS-XXT (PTFE diaphragm)
conguration only
(white)
PTFE
7
Apply Lubriplate (94276) to all “O" rings, ”U" cups and mating parts.
LUBRICATION / SEALANTS
Apply pipe sealant to threads.
Apply anti-seize compound to threads and bolt and nut ange heads which contact pump
case when using stainless steel fasteners.
Apply Loctite 242 to threads.
PD03P-XXX-XXX (en) Page 5 of 12
8
Air Side Santoprene
(tan)
Page 6
PARTS LIST / PD03P-XXX-XXX AIR MOTOR SECTION
Indicates parts included in 637428 Air Section Repair Kit.
p
Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]
101 Center Body (1) 96466 [PPG] 140 Valve Insert (1) 93276 [CK]
103R Cover
103L Cover
107 Plug, Small (1) 96353 [D]
111 Major Valve Spool (1) 95919 [D]
118 Actuator Pin (2) 94874-1 [SS] 168 “O” Ring
121 Washer (2) 96092 [D] 169 “U” Cup Packing
p
123 Screw
129 Mu er Ba e (1) 96542 [P]
130 Gasket (1) 9
132 Air Manifold Gasket (1) 96214-1 [B]
p
134 Flange Bolt
135 Valve Block (1) 96204 [PPG]
136 Plug, Large (1) 96352 [D] 236 Nut
137 “O” Ring
p
138 “U” Cup Packing
p
139 “U” Cup Packing
p
(right side)
(left side)
(#4 - 20 x 1/2”)
(1/4” - 20 x 3”)
(1/16” x 1-5/8” o.d.)
(1/8” x 1” o.d.)
(1/8” x 1-7/16” o.d.)
(1) 96488 [D] 141 Valve Plate (1) 96173 [CK]
(1) 96489 [D]
(12) 96093 [SS] 170 Spool Bushing (1) 96090 [D]
6531 [SY]
(4) 96487 [SS]
(3) Y325-29 [B]
(1) 94395 [U]
(1) 96383 [U] Lubriplate Grease, 10 Pack 637308
144 “U” Cup Packing
p
166 “O” Ring
p
167 Pilot Piston
p
171 “O” Ring
p
173 “O” Ring
p
174 “O” Ring
p
200 Porting Gasket (1) 96364 [B]
p
232 “O” Ring
p
(1/4” - 20)
Lubriplate FML-2 Grease (1) 94276
n p
(1/8” x 3/4” o.d.)
(1/16” x 1-1/4” o.d.)
(includes 168 and 169)
(1/16” x 7/16” o.d.)
(1/8” x 5/8” o.d.)
(1/16” x 13/16” o.d.)
(3/32” x 7/8” o.d.)
(3/32” x 11/32” o.d.)
(1/16” x 3/8” o.d.)
(2) Y187-47 [B]
(1) Y325-24 [B]
(1) 67382 [D]
(2) 96459 [U]
(1) 96384 [U]
(2) Y325-17 [B]
(2) Y325-115 [B]
(2) Y325-105 [B]
(4) Y325-10 [P]
(4) Y12-4-S [SS]
MATERIAL CODE
[B] = Nitrile [PPG] = Glass Filled Polypropylene
[CK] = Ceramic [SS] = Stainless Steel
[D] = Acetal [SY ] = Syn-Seal
[P] = Polypropylene [U] = Polyurethane
DIAPHRAGM PUMP SERVICE
GENERAL SERVICE NOTES:
Inspect and replace old parts with new parts as neces-
y
sary. Look for deep scratches on metallic surfaces, and
nicks or cuts in “O” rings.
Tools needed to complete disassembly and repair:
y
5/8” socket or wrench, 7/16” socket or wrench, 3/8”
y
socket or wrench, 5/16” Allen wrench, T-10 Torx
screwdriver, torque wrench (measuring inch pounds),
“O” ring pick.
FLUID SECTION DISASSEMBLY
Remove (61) top manifold.
1.
Remove (19) “O” rings, (21) seats and (22) balls.
2.
Remove (60) bottom manifold.
3.
Remove (19) “O” rings, (21) seats and (22) balls.
4.
Remove (15) uid caps.
5.
Remove (6) diaphragm nut, (7) or (7 / 8) diaphragms and
6.
(5) washer.
Remove (1) connecting rod from air motor.
7.
Carefully remove remaining (6) diaphragm nut, (7) or (7 / 8)
.
8
diaphragms and (5) washer from (1) connecting rod. Do
not mar surface of connecting rod.
FLUID SECTION REASSEMBLY
Reassemble in reverse order.
y
Lubricate (1) connecting rod with Lubriplate or equiva-
y
lent “O” ring lubricant.
Install (5) washers with i.d. chamfer toward diaphragm.
y
When replacing PTFE diaphragms, install the 96533-A
y
Santoprene diaphragm behind the Te on diaphragm.
AIR MOTOR SECTION SERVICE
Service is divided into two parts - 1. Pilot Valve, 2. Major
Valve.
Air Motor Section Service is continued from Fluid Section
y
repair.
PILOT VALVE DISASSEMBLY
Remove (123) screws, releasing (103) covers, (121) wash-
1.
ers, (118) actuator pins and (167) pilot piston.
.
Remove (170) spool bushing and inspect inner bore of
2
bushing for damage.
PILOT VALVE REASSEMBLY
Clean and lubricate parts not being replaced from ser-
1.
vice kit.
Assemble (171) “O” rings to (170) bushing and assemble
2.
bushing into (101) center body.
Lubricate and assemble (167) pilot piston assembly into
3.
(170) bushing.
Assemble (173 and 174) “O” rings and (121) washers to
4.
(103) covers, then insert (118) actuator pins through assembly.
Assemble (144) “U” cups (note the lip direction) and (103)
.
5
covers to (101) center body, securing with (123) screws.
NOTE: Tighten (123) screws to 4 - 6 in. lbs (0.45 - 0.68 Nm).
MAJOR VALVE DISASSEMBLY
Unthread (123) screws, releasing (129) mu er ba e.
1.
Unthread (134) bolts and pull (135) valve block and com-
2.
ponents from (101) center body.
Remove (132) gasket, (141) valve plate and (140) valve
3.
insert from (135) valve block.
Remove (134) bolts, releasing (107 and 136) plugs and
4.
(111) spool.
Page 6 of 12 PD03P-XXX-XXX (en)
Page 7
123
103L
PARTS LIST / PD03P-XXX-XXX AIR MOTOR SECTION
PILOT VALVE PARTS
144 169 168 171 118
Figure 4
173
107
137
166
135
134
138
139
137
140
MAJOR VALVE
167121 174 170
132
141 200 101
111
136
232 236
174
129130
123
144
103R
123
173 121118
PILOT VALVE PARTS
ASSEMBLY TORQUE REQUIREMENTS
(123) screw, 4 - 6 in. lbs (0.45 - 0.68 Nm).
(134) bolt, 15 - 20 in. lbs (1.7 - 2.3 Nm), wait 10 minutes, then re-torque to 15
NOTE: DO NOT OVERTIGHTEN FASTENERS.
- 20 in. lbs (1.7 - 2.3 Nm).
LUBRICATION / SEALANTS
Apply Lubriplate (94276) to all “O" rings, ”U" cups and mating parts.
Assemble (140) valve insert and (141) valve plate to
MAJOR VALVE REASSEMBLY
Assemble new (139 and 138) U” cups on (111) spool -
1.
LIPS MUST FACE EACH OTHER.
Assemble (137) O” rings to (136) large plug.
2.
Assemble (137 and 166) O” rings to (107) small plug.
3.
Insert (111) spool into (136) large plug, then insert (136)
4.
large plug into (135) valve block, being sure the (111)
spool is rotated to accept (140) valve insert.
Assemble (107) small plug into (135) valve block.
5.
PD03P-XXX-XXX (en) Page 7 of 12
6.
(135) valve block. Note: Assemble (140) valve insert with
dished” side toward (141) valve plate. Assemble (141)
valve plate with identi cation dot toward (132) gasket.
Assemble (132 and 200) gaskets and (135) valve block
7.
to (101) center body, securing with (134) bolts. NOTE:
Tighten (134) bolts to 15 - 20 in. lbs (1.7 - 2.3 Nm).
Assemble (130) gasket and (129) mu er ba e to (101)
8.
center body, securing with (123) screws. NOTE: Tighten
(123) screws to 4 - 6 in. lbs (0.45 - 0.68 Nm).
Page 8
TROUBLE SHOOTING
Product discharged from air exhaust.
Check for diaphragm rupture.
y
Check tightness of (6) diaphragm nut.
y
Air Bubbles in product discharge.
Check connections of suction plumbing.
y
Check “O” rings between intake manifold and uid caps.
y
Check tightness of (6) diaphragm nut.
y
Pump blows air out main exhaust when stalled on either
stroke.
Check “U” cups on (111) spool in major valve.
y
Check (141) valve plate and (140) insert for wear.
y
Check (169) U” cup on (167) pilot piston.
y
DIMENSIONAL DATA
Dimensions shown are for reference only, they are shown in inches and millimeters (mm).
Air Inlet 1/4 - 18 P.T.F. SAE Short
7-31/32" (202.3 mm)
4-13/32" (110.5 mm)
Pump blows air out main exhaust when stalled on either
stroke.
Check air supply.
y
Check for plugged outlet hose.
y
For the pump to prime itself, it must be mounted in the
y
vertical position so that the balls will check by gravity.
Check for pump cavitation - suction pipe should be sized
y
at least as large as the inlet thread diameter of the pump
for proper ow if high viscosity uids are being pumped.
Suction hose must be non-collapsible type, capable of
pulling a high vacuum.
Check all joints on intake manifolds and suction connec-
y
tions. These must be airtight.
Inspect the pump for solid objects lodged in the dia-
y
phragm chamber or the seat area.
Exhaust Port 1/2 - 14 N.P.T.F. - 1
5-23/32" (145.2 mm)
4-31/32" (125.6 mm)
9/32" Slot
(7.2 mm)
5-5/8" (142.7 mm)
2-13/16"
(71.4 mm)
Pump Model
PD03P-AXS-XXX
PD03P-BXS-XXX
9-5/16"
(236.2 mm)
4-3/8"
(111.0 mm)
“A" Material Inlet
3/8 - 18 N.P.T.F.
Rp 3/8 (3/8 - 19 BSP, parallel)
8-17/32"
(216.1 mm)
1-9/32"
(32.1 mm)
3/8" (9.6 mm) 4-1/16" (102.7 mm)
4-13/16" (121.9 mm)
“B" Material Outlet
3/8 - 18 N.P.T.F. - 1
Rp 3/8 (3/8 - 19 BSP, parallel)
1-3/32"
(27.8 mm)
Figure 5
Page 8 of 12 PD03P-XXX-XXX (en)
Page 9
67388 WALL MOUNT BRACKET ASSEMBLY
96507 Wall Mount Bracket
ACCESSORIES
Y13-3-T Washer (3)
Y14-10-S Lock Washer (3)
Y154-52-S Cap Screw (3)
(#10 - 24 x 1/2")
(3/16")
(#10)
Figure 6
PD03P-XXX-XXX (en) Page 9 of 12
Page 10
Page 10 of 12 PD03P-XXX-XXX (en)
Page 11
PD03P-XXX-XXX (en) Page 11 of 12
Page 12
PN 97999-1180
Page 12 of 12 PD03P-XXX-XXX (en)
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