Ingersoll-Rand PD02P Series User manual

E2003 CCN 99712788
&[phone] DFAX [phone]
INGERSOLL-RAND COMPANY
P.O. BOX 151 D ONE ARO CENTER D BRYAN, OHIO 43506Ć0151
OPERATOR’S MANUAL PD02P-X
RELEASED: 10-1-96
REVISED: 11-12-03
(REV. L)
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
1/4” 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 Servi e Kit Chart to mat h pump material with Servi e Kits ofĆ
fered. The X" represents a variable digit of the Model Number.
637276 Air Valve Kit.
637313ĆXX for Pump Wet End Repair (model digits 7 and 11).
637314ĆXX for Pump Rebuild (model digits 7 and 11).
PUMP DATA
Models see Model Des ription Chart" for ĆXXX".. . . . . . . .
Pump Type NonĆMetalli Air Operated Double Diaphragm.. . . . .
Material see ``Model Des ription Chart".. . . . . . . .
Weight Polypropylene 4.08 lbs (1.85 kgs). . . . . . . . . . . . .
Groundable A etal 4.64 lbs (2.10 kgs). . . . . .
PVDF (KynarR) 4.9 lbs (2.22 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 4.6 g.p.m. (17.4 liters). . . . . . . . . . . . . .
Maximum Suction Li t 20 ft. (water). . . . . . . . . . . . .
Maximum Output Per Cycle 0.014 gallons (53 's). . . . . . . . .
Maximum Particle Size lean fluid only. . . . . . . . . . . .
Maximum Temperature Limits
E.P.R. / EPDM Ć60_ to 280_ F (Ć51_ to 138_ C). . . . . . . . . . .
Groundable A etal 10_ to 180_ F (Ć12_ to 82_ C). . . . . . . .
Nitrile 10_ to 180_ F (Ć12_ to 82_ C). . . . . . . . . . . . . . . . .
Polypropylene 35_ to 150_ F (2_ to 66_ C). . . . . . . . . . .
PVDF (Kynar) 10_ to 200_ F (Ć12_ to 93_ C). . . . . . . . . . .
SantopreneRĆ40_ to 225_ F (Ć40_ to 107_ C). . . . . . . . . . .
T.F.E. (TeflonR)40_ to 225_ F (4_ to 107_ C). . . . . . . . . .
Groundable PD02PĆXDSĆDTX models only.. . . . . . . . . . . . . . . .
Dimensional Data see page 8.. . . . . . . . . . . . . . . .
Noise Level @ 70 p.s.i., 60 c.p.m. 59.8 db(A)¬. . . . .
¬The pump sound pressure levels published here have been updated to an Equivalent Continuous Sound
Level (LAeq) to meet the intent of ANSI S1.13Ć1971, CAGIĆPNEUROP S5.1 using four mi rophone lo aĆ
tions.
NOTICE: All possible options are shown in the chart. However, certain
combinations may not be recommended, consult a representative or the
actory i you have questions concerning availability.
PD02PĆXXSĆXTX
1/4" DIAPHRAGM PUMP
MODEL DESCRIPTION CHART
PD02 P Ć X X S Ć X T X
PD02P Ć X X S Ć X T X
637313 Ć X X
Diaphragm Material
Wet End Material
FLUID SECTION SERVICE KIT SELECTION
EXAMPLE: MODEL # PD02PĆADSĆDTA
FLUID SECTION SERVICE KIT # 637313ĆDA
WET END / FLUID CAP / MANIFOLD MATERIAL
D - Groundable A etal
K - PVDF (Kynar)
P - Polypropylene
CHECK VALVE SEAT MATERIAL
D - Groundable A etal
K - PVDF (Kynar)
P - Polypropylene
DIAPHRAGM / O" RING MATERIAL
A - Santoprene / E.P.R.
G - Nitrile / Nitrile
T - T.F.E. (Teflon) / T.F.E. (Teflon) / Nitrile
CENTER BODY MATERIAL
P - Polypropylene
INLET / OUTLET
A - Single Inlet / Single Outlet
D - Single Inlet / Double Outlet
E - Double Inlet / Single Outlet
H - Double Inlet / Double Outlet
HARDWARE MATERIAL
S - Stainless Steel
CHECK MATERIAL
T - T.F.E. (Teflon)

PD02PĆXPage 2 o 8
OPERATING AND SAFETY PRECAUTIONS
READ, UNDERSTAND, AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.
EXCESSIVE AIR PRESSURE
STATIC SPARK
HAZARDOUS MATERIALS
HAZARDOUS PRESSURE
WARNING EXCESSIVE AIR PRESSURE. Can cause personĆ
al injury, pump damage or property damage.
SDo not exceed the maximum inlet air pressure as stated on the
pump model plate.
SBe sure material hoses and other components are able to withĆ
stand luid pressures developed by this pump. Check all hoses
or 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.
SPD02PĆXDSĆDTX Groundable Acetal pumps: Use the pump
grounding screw provided. A screw terminal is provided on the
mani old. Connect a 12 ga. (min.) wire (66885Ć1 kit is available)
to a good earth ground source.
SThe pumping system and object being sprayed must be
grounded when it is pumping, lushing, recirculating or sprayĆ
ing lammable materials such as paints, solvents, lacquers,
etc. or used in a location where surrounding atmosphere is
conducive to spontaneous combustion.
SUse the pump grounding screw terminal provided. Use Aro
Part No. 66885Ć1 Ground Kit or connect a suitable ground wire
(12 ga. min.) to a good earth ground source.
SSecure pump, connections and all contact points to avoid
vibration and generation o contact or static spark.
SConsult local building codes and electrical codes or speci ic
grounding requirements.
SA ter grounding, periodically veri y continuity o electrical path
to ground. Test with an ohmmeter rom each component (e.g.,
hoses, pump, clamps, container, spray gun, etc.) to ground to
insure continuity. Ohmmeter should show 0.1 ohms or less.
SSubmerse the outlet hose end, dispensing valve or device in
the material being dispensed i possible. (Avoid ree streaming
o material being dispensed.)
SUse hoses incorporating a static wire.
SUse proper ventilation.
SKeep in lammables away rom heat, open lames and sparks.
SKeep containers closed when not in use.
WARNING Pump exhaust may contain contaminants. Can
cause severe injury. Pipe exhaust away rom work area and perĆ
sonnel.
SIn the event o a diaphragm rupture material can be orced out
o the air exhaust mu ler.
SPipe the exhaust to a sa e remote location when pumping hazĆ
ardous or in lammable materials.
SUse a grounded 1/4" minimum i.d. hose between the pump and
the mu ler.
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.
SDisconnect air supply line and relieve pressure rom the sysĆ
tem by opening dispensing valve or device and / or care ully
and slowly loosening and removing outlet hose or piping rom
pump.
WARNING HAZARDOUS MATERIALS. Can cause serious inĆ
jury or property damage. Do not attempt to return a pump to the
actory or service center that contains hazardous material.
Sa e handling practices must comply with local and national
laws and sa ety code requirements.
SObtain Material Sa ety Data Sheets on all materials rom the
supplier or proper handling instructions.
CAUTION Veri y the chemical compatibility o the pump
wetted parts and the substance being pumped, lushed or reĆ
circulated. Chemical compatibility may change with temperaĆ
ture and concentration o the chemical(s) within the
substances being pumped, lushed or circulated. For speci ic
luid compatibility, consult the chemical manu acturer.
CAUTION Maximum temperatures are based on mechaniĆ
cal stress only. Certain chemicals will signi icantly reduce
maximum sa e operating temperature. Consult the chemical
manu acturer or chemical compatibility and temperature limĆ
its. Re er to PUMP DATA on page 1 o this manual.
CAUTION Be certain all operators o this equipment have
been trained or sa e working practices, understand it's limitaĆ
tions, and wear sa ety goggles / equipment when required.
CAUTION Do not use the pump or the structural support o
the piping system. Be certain the system components are
properly supported to prevent stress on the pump parts.
SSuction and discharge connections should be lexible connecĆ
tions (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 o material or long periods
o time.
SDisconnect air line rom pump when system sits idle or long
periods o time.
CAUTION Use only genuine ARO replacement parts to asĆ
sure compatible pressure rating and longest service li e.
NOTICE Replacement warning labels are available upon
request: Static Spark & Diaphragm Rupture" PN \ 94080.
WARNING
CAUTION
NOTICE
= Hazards or unsa e practices which could
result in severe personal injury, death or
substantial property damage.
= Hazards or unsa e practices which could
result in minor personal injury, product or
property damage.
= Important installation, operation or
maintenance in ormation.

Page 3 o 8PD02PĆX
GENERAL DESCRIPTION
The ARO diaphragm pump offers high volume delivery even at low air
pressures, easy self priming and the ability to pump various vis osity
materials. The pump is designed to orrespond to the needs of the user
by offering a variety of wetted parts onfigurations to handle almost any
appli ation.
Air operated double diaphragm pumps utilize a pressure differential in
the air hambers to alternately reate su tion and positive fluid pressure
in the fluid hambers. Flat he ks insure a positive flow of fluid.
Pump y ling will begin as air pressure is applied and it will ontinue to
pump and keep up with the demand. It will build and maintain line presĆ
sure and will stop y ling on e maximum line pressure is rea hed (disĆ
pensing devi e losed) and will resume pumping as needed.
Model PD02PĆXDSĆDTX: The A etal material used in this pump onĆ
tains Stainless Steel fibers. It's ondu tivity allows it to be onne ted to a
suitable ground. A ground s rew is provided for this.
AIR AND LUBE REQUIREMENTS
WARNING EXCESSIVE AIR PRESSURE. Can cause pump
damage, personal injury or property damage.
SA filter apable of filtering out parti les larger than 50 mi rons should
be used on the air supply. In most appli ations there is no lubri ation
required other than the O" ring lubri ant whi h is applied during asĆ
sembly or repair.
SThe pump an be rotated 360_ to suit the appli ation. It may be
mounted upside down or on the wall with no effe t on su tion lift or
operating effi ien y. The filter and regulator need to be oriented in a
normal verti al dire tion to fun tion properly.
SPipe plugs are in luded for the material inlets. They an be swit hed
to a ommodate piping requirements. However, the fluid inlet must
always be in the port losest to the mounting base.
SWhen lubri ated air is ne essary, supply the air lubri ator with a
good grade of SAE 90 wt. nonĆdetergent oil and set the lubri ator to
a rate not to ex eed one drop per minute.
INSTALLATION
SNOTICE: ReĆtorque asteners prior to use. Re er to step #18 on
page 6 or in ormation.
SApply Teflon tape or pipe sealant to threads upon assembly to preĆ
vent leakage.
SSe ure the diaphragm pump legs to a suitable surfa e to insure
against damage by vibration.
STo avoid problems, install a parti le fluid filter to s reen out foreign
matter 1/32" (0.79 mm) or larger in diameter.
SThe pump is not re ommended for submerged appli ations.
SWhen the diaphragm pump is used in a for edĆfeed (flooded inlet)
situation, it is re ommended that a Che k Valve" be installed at the
air inlet.
OPERATING INSTRUCTIONS
SAlways flush the pump with a solvent ompatible with the material
being pumped, if the material being pumped is subje t to ``setting up"
when not in use for a period of time.
SDis onne t the air supply from the pump if it is to be ina tive for a few
hours.
SThe 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 restri tive. Be sure not to use hose
whi h might ollapse.
MAINTENANCE
Refer to the part list on page 4 for Servi e Kit Information, parts view on
page 5 and Repair Pro edures on page 6.
SCertain ARO Smart Parts" are indi ated whi h should be available
for fast repair and redu tion of down time.
SServi e kits are divided to servi e two separate diaphragm pump
fun tions: 1. Air Se tion, 2. Fluid Se tion. The Fluid Se tion is dividĆ
ed further to mat h typi al part Material Options.
SProvide a lean work surfa e to prote t sensitive internal moving
parts from ontamination from dirt and foreign matter during servi e
disassembly and reassembly.
SKeep good re ords of servi e a tivity and in lude pump in prevenĆ
tive maintenan e program.
S TeflonR is a registered trademark of the DuPont Company, S KynarR is a trademark of Penwalt Corp.,
S SantopreneR is a registered trademark of Monsanto Company, li ensed to Advan ed Elastomer Systems, L.P. S LubriplateR is a registered trademark of Lubriplate Division (Fiske Brothers)

PD02PĆXPage 4 o 8
PARTS LIST / PD02P-X
637276 Air Valve Kit: In ludes items 102, 111, 132, 134, 135, 137, 145, 146, 178, 179 and 94276 Lubriplate pa ket.
637313ĆXX Diaphragm Kit: In ludes items 7, 13, 19, 22, 33, 41, 64 and 94276 Lubriplate pa ket.
637314ĆXX Rebuild Kit: In ludes items 7, 13, 19, 22, 33, 41, 64, 102, 111, 119, 137, 144, 146, 147, 161 and 94276 Lubriplate pa ket.
DIAPHRAGM OPTIONS
7" 13" 19" 33" 64"
ĆXXX Diaphragm Qty [Mtl] BackĆUp Ring Qty [Mtl] Seal Qty [Mtl]
O" Ring
(.103" x .693" o.d.) Qty [Mtl]
O" Ring
(.157" x 3.424" o.d.) Qty [Mtl]
ĆXXA 93808 (2) [SP] 95127 (2) [T] 94434 (4) [E] 94437 (2) [E] ----- --- ---
ĆXXG 93808ĆG (2) [B] 95127 (2) [T] 94434ĆG (4) [B] 94438 (2) [T] ----- --- ---
ĆXXT 93898 (2) [T] 95127 (2) [T] 94435 (4) [T] 94438 (2) [T] 93947 (2) [B]
COMMON PARTS
PD02P Ć X X S Ć X T X POLYPROPYLENE ACETAL KYNAR
PD02PĆXPSĆPTX PD02PĆXDSĆDTX PD02PĆXKSĆKTX
Item Description (size in inches) Qty Part No. [Mtl] Part No. [Mtl] Part No. [Mtl]
j 1 Rod (2Ć13/16" long) (1) 93916 [C] 93916 [C] 93916 [C]
j 5 Washer (1Ć3/4" o.d.) (2) 94938 [Z] 94938 [Z] 94938 [Z]
j 6 Diaphragm Screw (1/4" Ć 20) (2) 93810Ć1 [P] 93810Ć2 [D1] 93810Ć3 [PK]
17 Mani old (Air Inlet) (1) 94246Ć1 [P] 94246Ć2 [G] 94246Ć4 [PK]
18 Mani old (1) 94247Ć1 [P] 94247Ć2 [G] 94247Ć4 [PK]
22 Disc (4) 94525 [T] 94525 [T] 94525 [T]
41 Spring Stop (4) 93814Ć1 [P] 93814Ć2 [D1] 93814Ć3 [PK]
43 Screw (#10 Ć 32 x 1") (4) 94436 [SS] 94436 [SS] 94436 [SS]
62 Nut (1/4" Ć 20) (6) 93828 [SS] 93828 [SS] 93828 [SS]
63 Pipe Plug (1/4 Ć 18 N.P.T.) (`) 93832Ć1 [P] 93832Ć2 [D2] 93832Ć3 [PK]
j 65 Fluid Cap (`) 94245Ć1 [P] 94245Ć2 [G] 94245Ć4 [PK]
j 66 Fluid Cap (with one blocked tube) (`) 94344Ć1 [P] 94344Ć2 [G] 94344Ć3 [PK]
j 68 Air Cap (with groove d)(1) 93804 [P] 93804 [P] 93804 [P]
j 69 Air Cap (with tongue Z)(1) 93805 [P] 93805 [P] 93805 [P]
74 Pipe Plug (3/8 Ć 18 N.P.T.) (`) 94478Ć1 [P] 94478Ć2 [D2] 94478Ć3 [PK]
131 Bolt (1/4" Ć 20 x 6.375") (6) 94526 [SS] 94526 [SS] 94526 [SS]
205 Logo Plate (2) 93919 [A] 93919 [A] 93919 [A]
AIR SECTION PARTS
Item Description (size in inches) Qty Part No. [Mtl] Item Description (size in inches) Qty Part No. [Mtl]
102 O" Ring (1/16" x 7/8" o.d.) (3) Y325Ć18 [B]
103 Bushing (1) 93917 [D2]
110 U" Cup (1/8" x 13/16" o.d.) (1) Y186Ć54 [B]
j 111 Spool Ass'y (includes items 110, 138, 180) (1) 67163 [D2]
119 O" Ring (.106" x .587" o.d.) (4) 15066 [B]
132 Gasket (1) 93809 [Kr]
134 Screw (#4 Ć 20 x .295") (3) 93942 [SS]
j 135 Valve Block (1) 93806 [R]
137 O" Ring (1/16" x 1" o.d.) (1) Y325Ć20 [B]
138 O" Ring (.103" x .818" o.d.) (1) 94760 [U]
144 U" Cup (1/8" x 5/8" o.d.) (2) Y186Ć45 [B]
j 145 Minor Valve Block (1) 93807 [R]
146 O" Ring (1/16" x 5/16" o.d.) (2) Y325Ć8 [B]
147 O" Ring (1/16" x 7/16" o.d.) (2) Y325Ć11 [B]
161 O" Ring (3/32" x 9/16" o.d.) (2) Y325Ć110 [B]
178 Trip Rod Assembly (includes items 119) (2) 65145 [D2]
179 Sleeve Assembly (includes items 119) (1) 65144 [D2]
180 O" Ring (.106" x .587" o.d.) (1) 15066ĆU [U]
MATERIAL CODE
[A] = Aluminum [E] = E.P.R. [P] = Polypropylene (Light Gray) [SS] = Stainless Steel
[B] = Nitrile [G] = Groundable A etal (Dark Gray) High Density Polypropylene (Green) [T] = Teflon
[C] = Carbon Steel [Kr] = Kraton [R] = Ryton [U] = Polyurethane
[D1] = A etal (Orange) [PK] = Pure Kynar [SP] = Santoprene [Z] = Zin
[D2] = A etal (White)
`Quantities will vary, depending on the inlet / outlet option sele ted (refer to hart on page 5).
VSmart Parts", keep these items on hand in addition to the Servi e Kits for fast repair and redu tion of down time.

Page 5 o 8PD02PĆX
PARTS LIST / PD02P-X
111
102
102
119
146
AIR VALVE SECTION
(SHOWN 2X SCALE)
Figure 2
LUBRICATION
Apply Lubriplate grease (94276) to all
O" rings, U" cups & mating parts.
. TORQUE REQUIREMENTS ,
NOTE: DO NOT OVERTIGHTEN FASTENERS
Figure 1
62 ,
18
134 ,
178
INLET / OUTLET FLUID CAP ITEM 63 ITEM 74
(Groove)
(Tongue)
OPTIONS A" B" Qty Qty
SI / SO 65 65 (1) (1)
SI / DO 66 65 - (1)
DI / SO 65 66 (1) -
DI / DO 66 66 - -
132
145
(6) / (5) Diaphragm nut / washer 75 Ć 85 in. lbs (8.5 Ć
9.6 Nm), use Loctite #242, tighten together.
(43) Torque to 20 Ć 25 in. lbs (2.3 Ć 2.8 Nm).
(62) / (131) Mani old bolts / nuts 70 in. lbs max. (7.9
Nm max.), tighten together alternately &
evenly, then reĆtorque.
(134) Torque to 3.5 Ć 4.5 in. lbs (0.40 Ć 0.51 Nm).
102
178179
146
135137180138110
19 41 22 B"
33 13 1 6976 ,645 144 144103
68 5 6476 ,
147 A" 161
17 63 43 ,
194122
74
131 ,
205
13 33 147 161

PD02PĆXPage 6 o 8
PUMP DISASSEMBLY AND REASSEMBLY
GENERAL PUMP REPAIR NOTES:
STools needed to omplete disassembly and repair:
S5/16" wren h or so ket, 7/16" so ket, 5/8" wren h or so ket, 3/8"
Allen wren h, spanner wren h, torque wren h (measuring in h
pounds), O" ring pi k.
SOn e the pump is disassembled, you have the opportunity to lean
and inspe t all parts for wear. Look for deep s rat hes on metalli
surfa es and ni ks or uts in O" rings. Repla e old parts with new
ones as ne essary.
STake pre autions to prevent utting O" rings upon installation.
SLubri ate ``O" rings and U" ups with Lubriplate. A pa ket of this luĆ
bri ant is in luded in ea h Servi e Kit.
SDo not overĆtighten fasteners. Refer to torque spe ifi ation blo k on
page 5.
SReĆtorque fasteners following restart.
Service Kits available. From your lo al distributor.
(Kits also in lude Lubriplate grease pa ket.)
SSERVICE KIT: 637314ĆXX ontains parts for a omplete pump rebuild.
SSERVICE KIT: 637276 ontains parts to rebuild the air valve.
SSERVICE KIT: 637313ĆXX ontains parts to rebuild the diaphragms
and he ks.
FLUID SECTION DISASSEMBLY
1. Pla e the pump on a flat workben h.
2. Using 7/16" so kets, remove six (62) nuts and (131) bolts.
3. Set the pump on end, with the air inlet" end up.
4. Using a flat blade s rewdriver, remove (17) air inlet manifold and
(A") fluid ap.
5. Remove (13) ba kĆup ring and (33) O" ring from (A") fluid ap.
6. Remove two (147) O" rings from (A") fluid ap.
7. Remove (18) manifold and (B") fluid ap.
8. Remove (13) ba kĆup ring and (33) O" ring from (B") fluid ap.
9. Using 5/8" wren hes on (6) diaphragm s rews, unthread and reĆ
move diaphragm assemblies.
SNOTE: Air valve se tion an be repaired at this time, refer to Air
Valve Disassembly".
10. Using a 5/16" wren h or flat blade s rewdriver, remove two (43)
s rews from (17) air inlet manifold.
11. Separate (17) air inlet manifold and (A") fluid ap. NOTE: (41)
spring stops and (22) dis s may fall out. If not, remove at this time.
12. Remove (19) seals and (161) O" rings.
13. Disassembly of the opposite end of the pump is the same as the air
inlet" end, ex ept for the following: a.) the opposite end does not
ontain (161) O" rings and b.) the top tube has the outside shoulder,
the bottom tube has the inside shoulder.
14. Wrap (1) rod in a shop rag and se ure in a softĆfa ed vise.
15. Using a 5/8" wren h, unthread (6) diaphragm s rew from (1) rod.
16. Using a 5/8" wren h on (6) diaphragm s rew and a spanner wren h
on (5) washer, unthread and remove (6) diaphragm s rew.
FLUID SECTION REASSEMBLY
NOTE: Lubri ate all O" rings, U" ups seals and their mating parts with
94276 Lubriplate upon assembly.
1. Pla e the new (7) diaphragms on the (6) diaphragm s rew, with the
bowed side of the diaphragm oriented against (6) diaphragm s rew.
2. Assemble (5) washer to (6) diaphragm s rew and torque to 75 Ć 85
in. lbs (8.5 Ć 9.6 Nm), using a spanner wren h and a 5/8" wren h.
NOTE: Be sure not to strip the plasti nut.
3. Assemble (1) rod to one of the diaphragm assemblies and tighten
finger tight.
4. Models PD02PĆXXSĆXTT only: Assemble (64) O" rings into
grooves in (68 and 69) air aps.
5. Assemble diaphragm assemblies into air aps and torque to 75 Ć 85
in. lbs (8.5 Ć 9.6 Nm), using 5/8" wren hes.
6. Assemble two (147) O" rings to the raised air passages, opposite
ea h other, inside (68) air ap.
7. Set (A") fluid ap on the workben h, with the tube side" down.
8. Assemble two (161) O" rings to ounterbores in (A") fluid ap.
9. Assemble (22) dis and (41) spring stop to the he k seat nearest the
top tube of (A") fluid ap (top tube has the shoulder on the outside).
10. Assemble (41) spring stop and (22) dis (dis on top) to he k seat
nearest the bottom tube (shoulder on outside).
11. Lubri ate seal grooves in (17) air inlet manifold and assemble (19)
seals to grooves.
12. Assemble (17) air inlet manifold to (A") fluid ap, aligning fluid inlet
with lower tube (shoulder on outside).
13. Se ure with two (43) s rews. Torque to 20 Ć 25 in. lbs (2.3 Ć 2.8 Nm),
using a 5/16" wren h.
14. Repeat steps 9 thru 13 for opposite end of pump. NOTE: The tubes
are reversed on (B") fluid ap (top tube has outside shoulder).
15. Assemble (33) O" rings and (13) ba kĆup rings to the outside shoulĆ
der of tubes of (A" and B") fluid aps.
16. Assemble (17) air inlet manifold and omponents into (68) air ap,
being sure to align groove in manifold with rib in air ap.
17. Assemble (18) manifold and omponents into (69) air ap, being
sure to align groove in manifold with rib in air ap.
18. Assemble six (131) bolts and (62) nuts to pump and torque to 70 in.
lbs max (7.9 Nm max), using 7/16" so kets, hold the nut, torque the
bolt only. NOTE: Allow the pump to sit for at least 15 minutes, then
reĆtorque bolts to 70 in. lbs max (7.9 Nm max).
AIR VALVE SECTION DISASSEMBLY
1. Refer to Fluid Se tion Disassembly", steps 1 thru 9.
2. Separate (68 and 69) air aps, releasing (103) bushing and logo
plates.
3. Remove air valve assembly, (102, 137 and 146) O" rings and (144)
U" ups from air aps.
4. Remove (111) spool assembly, (178) trip rods and (179) sleeve asĆ
sembly from (145) valve blo k.
5. Remove O" rings and U" up from (111) spool assembly.
6. Inspe t (119) O" rings on (178) trip rods and (179) sleeve assembly.
7. Remove three (134) s rews, releasing (145) minor valve blo k and
(132) gasket.
AIR VALVE SECTION REASSEMBLY
1. Assemble (132) gasket and (145) minor valve blo k to (135) valve
blo k, se uring with three (134) s rews. NOTE: Torque to 3.5 Ć 4.5
in. lbs (0.40 Ć 0.51 Nm).
2. Assemble (119) O" rings to (178) trip rods and (179) sleeve assembly.
3. Assemble (178) trip rods and (179) sleeve assembly into (145) valve
blo k.
4. Assemble (138 and 180) O" rings and (110) U" up to (111) spool
assembly.
5. Assemble (111) spool assembly into (135) valve blo k, with small
end of spool going into valve blo k first.
6. Assemble (102, 137 and 146) O" rings to valve blo k.
7. Assemble (144) U" ups to (68 and 69) air aps.
8. Pla e one (68 or 69) air ap on end, with legs down and seat valve
blo k into air ap.
9. Assemble logo plates and (103) bushing into air ap.
10. Assemble other air ap to air ap, aligning logo plates, (178) trip rod
and (103) bushing.
11. Refer to Fluid Se tion Reassembly", steps 5 thru 18 to omplete
reassembly.

Page 7 o 8PD02PĆX
TROUBLE SHOOTING
Air Motor stalls.
SChe k for blown diaphragm
SChe k for damaged O" rings on the spool.
SChe k for damaged O" rings on the trip rod.
SChe k valve blo k gasket for leakage.
Air leaks rom exhaust.
SChe k for damaged O" rings on the valve blo k, spool or trip rod.
SChe k gasket between valve blo ks for leakage.
SU" ups on onne ting rod bushing are damaged or installed ba kĆ
wards.
Fluid leaks rom exhaust.
SChe k for diaphragm damage.
SChe k for diaphragm s rews not adequately torqued.
Low low or pump continues to cycle a ter shutĆo .
SChe k for trapped air if the pump is oriented where the inlet he k is
above the outlet he k. Temporarily in rease the flow or reĆprime
the pump.
SChe k for damaged seats or foreign matter logging the he k asĆ
sembly.
Air leaks rom pump (other than exhaust).
SChe k for bolts not evenly or adequately torqued.
SChe k for O" ring missing / damage between the fluid ap and the
air ap on the air inlet side.
External luid leaks rom pump.
SChe k for bolts not properly torqued.
SChe k for damaged O" rings on the fluid ap tubes.
SChe k for damaged O" rings on the valve he k.
SChe k for damaged diaphragm seal.
Pump operates but dispenses little or no luid.
SChe k for obstru tion in fluid line.
SChe k for foreign matter logging he k assemblies.
Note: Install a fluid s reen on the material inlet hose if the problem
ontinues.
SSu tion line too small.
SChe k for air leakage at the air / fluid inlet pipe plugs. Use teflon tape
or pipe sealant upon assembly.
TYPICAL CROSS SECTION

PD02PĆXPage 8 o 8
DIMENSIONAL DATA
1/4 Ć 18 N.P.T.F. Ć 1 Outlet
www.arozone.com
Dimensions shown are for referen e only. They are shown in in hes and millimeters (mm).
11/16" (17 mm)
1Ć5/32" (30 mm)
SIDE VIEW
END VIEWS
1Ć5/32" (30 mm)
11/16" (17 mm)
5/16" (8 mm) SLOT
3/8 Ć 18 N.P.T.F. Ć 1 Inlet
1/4 Ć 18 P.T.F. Air Inlet
1/4 Ć 18 N.P.T.F. Ć 1 Outlet
1/4 Ć 18 P.T.F. Exhaust
3/8 Ć 18 N.P.T.F. Ć 1 Inlet
4Ć3/4" (121 mm)
5Ć1/2" (140 mm)
4Ć13/32"
(112 mm)
1Ć9/32"
(32 mm)
4Ć17/32"
(115 mm)
1Ć3/8"
(35 mm)
8Ć1/32" (205 mm)
6Ć1/2" (165 mm)
7Ć9/32" (185 mm)
5Ć5/8"
(143 mm)
A FULL SIZE VERSION OF THIS MANUAL IS AVAILABLE UPON REQUEST (PN 97999Ć681)
PN 97999Ć680