OPERATOR’S MANUAL
PD07X-X-X
RELEASED:
REVISED:
(REV. 04)
2-20-07
5-21-10
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
3/4" DIAPHRAGM PUMP
1:1 RATIO (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 mate-
rial options.
637427-XX for fluid section repair (see page 4).
637428 for air section repair (see page 6).
PUMP DATA
Models. . . . . . . . . . . . . see Model Description Chart for “-XXX”
Pump Type. . . . . . . . . Air Operated Double Diaphragm
Material. . . . . . . . . . . . see Model Description Chart
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.74 lbs (3.96 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)
Figure 1
Air Consumption @ 40 p.s.i.. . . . . . . 1 c.f.m. / gallon (approx.)
(flooded inlet)
Maximum Flow Rate
. . . 13.6 g.p.m. (51.5 l.p.m.)
MODEL DESCRIPTION CHART
Displacement / Cycle @ 100 p.s.i.g. . 0.030 gal. (0.11 lit.)
Maximum Particle Size . . . . . . . . . . . . . 3/32”dia. (2.4 mm)
Maximum Temperature Limits (diaphragm / ball / seat
material)
PD07R - X A S - X X X
Hytrel® . . . . . . . . . . . . . . . . . . . -20° to 150° F (-29° to 66° C)
Polypropylene . . . . . . . . . . . . 35° to 175° F (2° to 79° C)
Santoprene®. . . . . . . . . . . . . . -40° to 225° F (-40° to 107° C)
PTFE . . . . . . . . . . . . . . . . . . . . . 40° to 225° F (4° to 107° C)
Dimensional Data. . . . . . . . . . . . . . . . . . . see page 8
Center Section Material
R - Polypropylene
Fluid Connection
A - 3/4 - 14 N.P.T.F. - 2
B - Rp 3/4 (3/4 - 14 BSP, parallel)
Noise Level @ 70 p.s.i., 60 c.p.m.. . . . . . 75.0 db(A)
c
Fluid Cap & Manifold Material
The pump sound pressure levels published here have been updated to
an Equivalent Continuous Sound Level (LAeq) to meet the intent of ANSI
S1.13-1971, CAGI-PNEUROP S5.1 using four microphone locations.
c
A - Aluminum
Hardware Material
S - Stainless Steel
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.
Seat Material
F - Aluminum
P - Polypropylene
Ball Material
A - Santoprene
C - Hytrel
T - PTFE
Diaphragm Material
A - Santoprene
C - Hytrel
T - PTFE / Santoprene
Fluid Section Service Kit Selection
PD07R - XAS - X X X
637427 - X X
EXAMPLE: Model #PD07R-AAS-PCC
Fluid Section Service Kit # 637427-CC
Ball
Diaphragm
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET -- BRYAN, OHIO 43506
ꢀ
© 2010
CCN 15275290
(800) 495-0276 FAX (800) 892-6276
OPERATING INSTRUCTIONS
WARNING = Hazards or unsafe practices which
could result in severe personal injury,
death or substantial property damage.
CAUTION = Hazards or unsafe practices which
could result in minor personal injury,
product or property damage.
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.
Disconnect the air supply from the pump if it is to be in-
active for a few hours.
The outlet material volume is governed not only by the
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 col-
lapse.
When the diaphragm pump is used in a forced-feed
(flooded inlet) situation, it is recommended that a “check
valve”be installed at the air inlet.
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NOTICE
= Important installation, operation or
maintenance information.
GENERAL DESCRIPTION
The ARO diaphragm pump offers high volume delivery even
at low air pressure and a broad range of material compatibil-
ity options are available. Refer to the model and option chart.
ARO pumps feature stall resistant design, modular air motor
/ fluid sections.
Air operated double diaphragm pumps utilize a pressure dif-
ferential in the air chambers to alternately create suction and
a positive fluid pressure in the fluid chambers, ball checks
insure a positive flow of fluid.
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Secure the diaphragm pump legs to a suitable surface to
insure against damage by vibration.
MAINTENANCE
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 maxi-
mum line pressure is reached (dispensing device closed) and
will resume pumping as needed.
Certain ARO “Smart Parts” are indicated which should be
available for fast repair and reduction of down time.
Provide a clean work surface to protect sensitive internal
moving parts from contamination from dirt and foreign
matter during service disassembly and reassembly.
Keep good records of service activity and include the
pump in preventive maintenance program.
Service kits are available to service two separate dia-
phragm pump functions: 1. AIR SECTION, 2. FLUID SEC-
TION. The Fluid Section is divided further to match typical
active Material Options.
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AIR AND LUBE REQUIREMENTS
WARNING EXCESSIVE AIR PRESSURE. Can cause pump
damage, personal injury or property damage.
A filter capable of filtering out particles larger than 50
microns should be used on the air supply. There is no lu-
brication required other than the “O” ring lubricant which
is applied during assembly or repair.
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Before disassembling, empty captured material in the
outlet manifold by turning the pump upside down to
drain material from the pump.
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If lubricated air is present, make sure that it is compatible
with the “O” rings and seals in the air motor section of the
pump.
Hytrel® is registered trademarks of the DuPont Company Santoprene® is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P.
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Lubriplate® is a registered trademark of Lubriplate Division (Fiske Brothers Refining Company) ARO® is a registered trademark of Ingersoll-Rand Company
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PD07X-X-X (en)
Page 3 of 8
PARTS LIST / PD07X-X-X FLUID SECTION
637427-XX Fluid Section Service Kits include: Balls (see Ball Option, refer to -XX in chart below), Diaphragms (see Diaphragm Op-
tion, refer to -XX in chart below), and item 19 (listed below) plus items 144, 174 and 94276 Lubriplate® FML-2 grease (page 6).
SEAT OPTIONS
PD07R-XAS-XXX
“21”
BALL OPTIONS
MATERIAL CODE
PD07R-XAS-XXX
[A]
[B]
[E]
= Aluminum
= Nitrile
= E.P.R.
“22” (3/4” diameter)
-XXX Seat
-FXX 95727
-PXX 93098-10
Qty [Mtl]
(4)
(4)
-XXX Ball
Qty [Mtl]
(4) [Sp]
(4)
(4)
[GFN] = Glass Filled Nylon
[H]
[P]
= Hytrel
= Polypropylene
[Sp] = Santoprene
[SS] = Stainless Steel
[A]
[P]
-XAX 93100-E
-XCX 93100-C
-XTX 93100-4
[H]
[T]
[T]
= PTFE
DIAPHRAGM OPTIONS PD07R-XAS-XXX
(3/32” x 1-5/16” o.d.)
Service Kit
“7”
“8”
“19”
-XX = (Ball)
-XXX -XX = (Diaphragm) Diaphragm Qty [Mtl] Diaphragm Qty [Mtl] “O” Ring
Qty [Mtl]
-XXA 637427-XA
-XXC 637427-XC
-XXT 637427-XT
93465
93465-9
93111
(2) [Sp] - - - - -
- - -
- - -
- - - 93763
- - - Y325-122
(4)
(4)
(4)
[E]
[B]
[T]
(2)
(2)
[H] - - - - -
[T] 93465
(2) [Sp] 93265
COMMON PARTS
(size)
(size)
Item Description
Qty Part No.
[Mtl]
[SS]
[GFN]
[SS]
[A]
Item Description
Qty Part No.
(1) 92956-1
(1) 66885-1
[Mtl]
[SS]
- - -
(see page 7)
(not shown)
1
5
6
Connecting Rod
Diaphragm Washer
Diaphragm Washer
(1) 96379
(2) 94645
(2) 94622
(4) 95092
(2) 94628
(2) 95064
(8) 96176
(16) 93095
(16) 93886
43 Ground Strap
57 Ground Kit Assembly
60
†
Inlet Manifold
PD07R-AAS-XXX (N.P.T.)
†
12 Washer
(1) 96606-1
(1) 96606-2
[A]
[A]
(5/16” - 18 x 3/4”)
PD07R-BAS-XXX (BSP)
14 Flange Bolt
15 Fluid Cap
26 Flange Bolt
[SS]
[A]
Outlet Manifold
PD07R-AAS-XXX (N.P.T.)
PD07R-BAS-XXX (BSP)
61
(5/16” - 18 x 7/8”)
(5/16" - 18)
[SS]
[SS]
[SS]
(1) 96604-1
(1) 96604-2
[A]
[A]
(5/16” - 18 x 1-1/4”)
27 Bolt
29 Hex Flange Nut
“Smart Parts”, keep these items on hand in addition to the service kit for fast repair and reduction of down time.
†
TYPICAL CROSS SECTION
Figure 2
Page 4 of 8
PD07X-X-X (en)
PARTS LIST / PD07X-X-X FLUID SECTION
COLOR CODE
3
2
1
4
FOR THE AIR MO-
TOR SECTION, SEE
PAGES 6 & 7.
Diaphragm
Color
Ball
Material
Color
5
7
8
6
Hytrel
Cream
Tan
White
Black (
Tan
)
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Santoprene
PTFE
White
(
y
) Dot
61
26
Torque Sequence
„
(
„
27
1
5
7
6
14
œ
(
22
12
21
19
œ
(
„
29
15
„
26
60
(
22
12
21
19
œ
Figure 3
View for PD07R-XAS-XXT (PTFE diaphragm) configuration
only.
Fluid side PTFE (white)
7
TORQUE REQUIREMENTS
)
(
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(14) Bolt, 95 - 105 in. lbs (10.7 - 11.9 Nm).
(26) Bolt, 50 - 60 in. lbs (5.6 - 6.8 Nm), / alternately and evenly, then re-
torque after initial run-in.
(29) Nut, 50 - 60 in. lbs (5.6 - 6.8 Nm), / alternately and evenly, then re-
torque after initial run-in.
LUBRICATION / SEALANTS
Apply Lubriplate FML-2 grease (94276) to all “O” rings, “U” cups and
mating parts.
œ
„
Apply anti-seize compound to threads and bolt and nut flange heads
which contact pump case when using stainless steel fasteners.
Air side Santoprene (tan)
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PD07X-X-X (en)
Page 5 of 8
PARTS LIST / PD07X-X-X AIR MOTOR SECTION
Indicates parts included in 637428 air section repair kit.
9
AIR MOTOR PARTS LIST
(size)
(size)
Item Description
(Qty) Part No.
(1) 96315
(1) 96091
(1) 96351
(1) 96353
(1) 95919
(2) 94874-1
(2) 96092
(8) 96093
(1) 67367
(1) 67366
(1) 93107
(1) 96214-1
(4) 94871
(1) 96204
(1) 96352
(3) Y325-29
(1) 94395
(1) 96383
(1) 93276
[Mtl]
[PPG]
[D]
[D]
[D]
[D]
[SS]
[D]
[SS]
[PPG]
[PPG]
[SY]
[B]
[SS]
[PPG]
[D]
[B]
[U]
[U]
[CK]
Item Description
(Qty) Part No.
[Mtl]
101 Center Body
141 Valve Plate
144 “U” Cup Packing
166 “O” Ring
167 Pilot Piston
168 “O” Ring
169 “U” Cup Packing
170 Spool Bushing
171 “O” Ring
173 “O” Ring
174 “O” Ring
(1) 96173
[CK]
[B]
[B]
[D]
[U]
[U]
[D]
[B]
[B]
[B]
[B]
[C]
[B]
- - -
(right side)
(left side)
(3/16” x 1” o.d.)
103R Cover
103L Cover
(2) Y187-48
(1) Y325-24
(1) 67382
(2) 96459
(1) 96384
9
9
9
(1/16” x 1-1/4” o.d.)
(includes 168 and 169)
107 Plug, Small
111 Major Valve Spool
118 Actuator Pin
121 Washer
(1/16” x 7/16” o.d.)
(1/8" x 5/8" o.d.)
(1) 96090
(#4 - 20 x 1/2”)
(1/16” x 13/16” o.d.)
123 Screw
(2) Y325-17
(2) Y325-115
(2) Y325-105
(1) 96364
(1) 93110
(4) Y325-10
(1) 637438
9
9
9
9
(3/16” x 7/8” o.d.)
(3/32” x 11/32” o.d.)
129 Muffler Assembly
(optional)
129 Exhaust Cover
™
™
9
(optional)
130 Gasket
200 Porting Gasket
201 Muffler
232 “O” Ring
(optional)
132 Air Manifold Gasket
(1/4” - 20 x 5-3/4”)
(1/16” x 3/8” o.d.)(optional)
134 Flange Bolt
135 Valve Block
136 Plug, Large
™
(includes items
Ported Exhaust Kit
™
129, 130 and 232) (optional)
(1/16” x 1-5/8” o.d.)
137 “O” Ring
9
9
9
(1/8” x 1” o.d.)
138 “U” Cup Packing
139 “U” Cup Packing
140 Valve Insert
Lubriplate FML-2 Grease
Lubriplate Grease, 10 Pack
(1) 94276
637308
9
(1/8” x 1-7/16” o.d.)
MATERIAL CODE
lent “O”ring lubricant.
Connecting rod (1) should be installed using 96571 bul-
let, included in service kit.
Install (5) washers with i.d. chamfer toward diaphragm.
When replacing PTFE diaphragms, install the 93465
Santoprene diaphragm behind the PTFE diaphragm.
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[B] = Nitrile
[PPG] = Glass Filled Polypropylene
[SS] = Stainless Steel
[SY] = Syn-Seal
[C] = Carbon Steel
[CK] = Ceramic
[D] = Acetal
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[U] = Polyurethane
DIAPHRAGM PUMP SERVICE
GENERAL SERVICE NOTES:
AIR MOTOR SECTION SERVICE
Service is divided into two parts - 1. Pilot Valve, 2. Major
Inspect and replace old parts with new parts as neces-
sary. Look for deep scratches on metallic surfaces, and
nicks or cuts in “O”rings.
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Valve.
Tools needed to complete disassembly and repair:
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Air Motor Section service is continued from Fluid Section
repair.
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7/8” socket or wrench, 1/2” socket or wrench, 3/8”
socket or wrench, 3/8” Allen wrench, T-10 Torx screw-
driver, torque wrench (measuring inch pounds), “O”
ring pick.
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PILOT VALVE DISASSEMBLY
1.
2.
Remove (123) screws, releasing (103) covers, (121) wash-
ers, (118) actuator pins and (167) pilot piston.
Remove (170) spool bushing and inspect inner bore of
bushing for damage.
FLUID SECTION DISASSEMBLY
1.
2.
Remove (61) top manifold.
Remove (19) “O” rings, (21) seats, (12) washers and (22)
balls.
PILOT VALVE REASSEMBLY
Clean and lubricate parts not being replaced from service
3.
4.
Remove (60) bottom manifold.
Remove (19) “O” rings, (21) seats, (12) washers and (22)
balls.
Remove (15) fluid caps.
Remove (14) bolt, (6) diaphragm washer, (7) or (7 / 8) dia-
phragms and (5) washer.
Remove (1) connecting rod from air motor.
Carefully remove remaining (14) bolt, (6) diaphragm
washer, (7) or (7 / 8) diaphragms and (5) washer from (1)
connecting rod. Do not mar surface of connecting rod.
1.
2.
3.
4.
kit.
Assemble (171) “O” rings to (170) bushing and assemble
bushing into (101) center body.
Lubricate and assemble (167) pilot piston assembly into
(170) bushing.
Assemble (173 and 174) “O” rings and (121) washers to
(103) covers, then insert (118) actuator pins through as-
sembly.
Assemble (144) “U” cups (note the lip direction) and (103)
covers to (101) center body, securing with (123) screws.
NOTE: Tighten (123) screws to 4 - 6 in. lbs (0.45 - 0.68 Nm).
5.
6.
7.
8.
5.
FLUID SECTION REASSEMBLY
Reassemble in reverse order.
Lubricate (1) connecting rod with Lubriplate or equiva-
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Page 6 of 8
PD07X-X-X (en)
PARTS LIST / PD07X-X-X AIR MOTOR SECTION
PILOT VALVE PARTS
637438 (optional)
144 118 169
168
171
232
130
129
201 (optional)
œ
œ
œ
œ
123
)
103L
173
œ
174 121 167 170
œ
140
132
107
137
166
129
œ
œ
144
œ
135
134
138
103R
123
)
œ
(
118 121 174
173
œ
œ
141
200
101
43
œ
œ
139
137
PILOT VALVE PARTS
œ
œ
111
136
) TORQUE REQUIREMENTS (
NOTE: DO NOT OVERTIGHTEN FASTENERS.
MAJOR VALVE
(123) Torque to 4 - 6 in. lbs (0.45 - 0.68 Nm).
(134) Torque to 15 - 20 in. lbs (1.7 - 2.3 Nm), wait 10 minutes, then
re-torque to 15 - 20 in. lbs (0.45 - 0.68 Nm).
LUBRICATION / SEALANTS
œ Apply Lubriplate FML-2 grease to all “O” rings, “U” cups and
mating parts.
Figure 4
MAJOR VALVE DISASSEMBLY
MAJOR VALVE REASSEMBLY
1.
2.
1.
Unthread (134) bolts, releasing (129) muffler assembly.
Pull (135) valve block and components from (101) center
body.
Remove (132) gasket, (141) valve plate and (140) valve
insert from (135) valve block.
Remove (134) bolts, releasing (107 and 136) plugs and
(111) spool.
Assemble new (138 and 139) “U” cups on (111) spool -
LIPS MUST FACE EACH OTHER.
2.
3.
4.
Assemble (137) “O”rings to (136) large plug.
3.
4.
Assemble (137 and 166) “O”rings to (107) small plug.
Insert (111) spool into (136) large plug, then insert (136)
large plug into (135) valve block, being sure the (111)
spool is rotated to accept (140) valve insert.
5.
6.
Assemble (107) small plug into (135) valve block.
Assemble (140) valve insert and (141) valve plate to
(135) valve block. NOTE: Assemble (140) valve insert with
“dished” side toward (141) valve plate. Assemble (141)
valve plate with identification dot toward (132) gasket.
Assemble (132 and 200) gaskets, (135) valve block and
(129) muffler assembly to (101) center body, securing
with (134) bolts. NOTE: Tighten (134) bolts to 15 - 20 in.
lbs (1.7 - 2.3 Nm).
7.
PD07X-X-X (en)
Page 7 of 8
TROUBLE SHOOTING
Product discharged from air exhaust.
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Low output volume.
Check for diaphragm rupture.
Check tightness of (14) bolt.
Check air supply.
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Check for plugged outlet hose.
For the pump to prime itself, it must be mounted in the
vertical position so that the balls will check by gravity.
Check for pump cavitation - suction pipe should be sized
at least as large as the inlet thread diameter of the pump
for proper flow if high viscosity fluids are being pumped.
Suction hose must be non-collapsible type, capable of
pulling a high vacuum.
Air bubbles in product discharge.
Check connections of suction plumbing.
Check “O”rings between intake manifold and fluid caps.
Check tightness of (14) bolt.
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Pump blows air out main exhaust when stalled on either
stroke.
Check all joints on the intake manifolds and suction con-
nections. These must be air tight.
Inspect the pump for solid objects lodged in the dia-
phragm chamber or the seat area.
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Check “U”cups on (111) spool in major valve.
Check (141) valve plate and (140) insert for wear.
Check (169) “U”cup on (167) pilot piston.
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DIMENSIONAL DATA
Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
(Outlet) P
Air Inlet 1/4 - 18 P.T.F. SAE Short
E
L
F
G
N
B
D
K
M
H
C
J
A
(Inlet) P
DIMENSIONS
A - 9-9/32”(235.3 mm)
E - 6-23/32” (170.6 mm) J - 5-1/2" (139.7 mm)
N - 6-5/16" (159.8 mm)
P - see below
B - 11-1/16”(280.4 mm) F - 6” (152.4 mm)
K - 5/16” (8.0 mm)
Figure 5
C - 6-1/8”(155.6 mm)
D - 2”(50.8 mm)
G - 11-7/8” (301.2 mm)
L - 3-29/32” (99.2 mm)
H - 4-29/32” (124.2 mm) M - 3/8” (9.5 mm)
Pump Model
PD07R-AAS-XXX
PD07R-BAS-XXX
“P”Material Inlet / Outlet
3/4 - 14 N.P.T.F. - 2
Rp 3/4 (3/4 - 14 BSP, parallel)
PN 97999-1226
PD07X-X-X (en)
Page 8 of 8
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