OPERATOR’S MANUAL
PD05P-XXX-XXX
RELEASED:
REVISED:
(REV. J)
5-15-98
11-12-10
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
1/2" 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.
637140-XX for fluid section repair (see page 4).
637141 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 . . . . . PD05P-AAS-XXX . . . . . . . 8.36 lbs (3.79 kgs)
PD05P-ASS-XXX. . . . . . . . 14.6 lbs (6.62 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)
Figure 1
Maximum Outlet Pressure . . . . . . . . . . 100 p.s.i.g. (6.9 bar)
Air Consumption @ 40 p.s.i.. . . . . . . 1 c.f.m. / gallon (approx.)
MODEL DESCRIPTION CHART
(flooded inlet)
Maximum Flow Rate
. . . 13 g.p.m. (49.2 l.p.m.)
Displacement / Cycle @ 100 p.s.i.g. . 0.040 gal. (0.15 lit.)
Maximum Particle Size . . . . . . . . . . . . . 3/32”dia. (2.4 mm)
Maximum Temperature Limits (diaphragm / ball / seat
material)
PD05 P - A X S - X X X
Center Section Material
P - Polypropylene
Nitrile . . . . . . . . . . . . . . . . . . . . 10° to 180° F (-12° to 82° 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)
Viton® . . . . . . . . . . . . . . . . . . . . -40° to 350° F (-40° to 177° C)
Dimensional Data. . . . . . . . . . . . . . . . . . . see page 8
Fluid Connection
A - 1/2 - 14 N.P.T.F. - 1
Fluid Cap & Manifold Material
A - Aluminum
S - Stainless Steel
Noise Level @ 70 p.s.i., 60 c.p.m.. . . . . . 71.1 db(A)
c
Hardware Material
S - Stainless Steel
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
Seat Material
F - Aluminum
P - Polypropylene
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.
Ball Material
A - Santoprene
G - Nitrile
S - Stainless Steel
T - PTFE
V - Viton
Diaphragm Material
A - Santoprene
G - Nitrile
T - PTFE / Santoprene
V - Viton
Fluid Section Service Kit Selection
PD05P - AXS - X X X
637140 - X X
EXAMPLE: Model #PD05P-ASS-SAA
Fluid Section Service Kit # 637140-AA
Ball
Diaphragm
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET – BRYAN, OHIO 43506
(800) 495-0276 FAX(800) 892-6276
© 2010
CCN 99713398
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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.
TYPICAL CROSS SECTION
Models PD05P-ASS-XXX
(Stainless Steel)
Models PD05P-AAS-XXX
(Aluminum)
Figure 2
PD05P-XXX-XXX (en)
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PARTS LIST / PD05P-XXX-XXX FLUID SECTION
637140-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 items 2 and 19 (listed below) plus 93706-1 Key-Lube grease packet (page 6).
SEAT OPTIONS
PD05P-AXS-XXX
“21”
BALL OPTIONS
PD05P-AXS-XXX
MATERIAL CODE
[A]
[B]
[C]
[E]
[F]
= Aluminum
= Nitrile
= Carbon Steel
= E.P.R.
“22”
“19”
(3/4” diameter)
-XXX Ball Qty [Mtl] “O” Ring
(4) [Sp] 93763
(3/32” x 1-5/16” o.d.)
= Flouraz®
-XXX Seat
Qty [Mtl]
Qty [Mtl]
[GFN] = Glass Filled Nylon
[P] = Polypropylene
[Sp] = Santoprene
-FXX
-PXX
-SXX
95727
93098-10
93409-1
(4)
(4)
(4)
[A]
[P]
[SS]
-XAX 93100-E
-XGX 93100-2
93410-1
-XTX 93100-4
-XVX 93100-3
(4)
(4)
(4)
(4)
(4)
[E]
[B]
[F]
[T]
[V]
(4)
(4)
(4)
(4)
[B] Y325-122
[SS] 93764
[T] 93265
[SS] = Stainless Steel
[T]
[V]
= PTFE
= Viton
-XSX
[V] Y327-122
DIAPHRAGM OPTIONS PD05P-AXS-XXX
Service Kit
“7”
“8”
-XX = (Ball)
-XXX -XX = (Diaphragm) Diaphragm Qty [Mtl] Diaphragm Qty [Mtl]
-XXA 637140-XA
-XXG 637140-XG
93465
93465-G
93111
(2) [Sp] - - - - -
- - -
- - -
(2) [Sp]
- - -
- - -
(2)
(2)
(2)
[B] - - - - -
[T] 93465
[V] - - - - -
-XXT
637140-XT
-XXV 637140-XV
93581-3
- - -
- - -
WETTED COMMON PARTS PD05P-AXS-XXX
Stainless Steel
Aluminum
PD05P-ASS-XXX
PD05P-AAS-XXX
(size)
Item Description
Qty Part No.
(1) 93084
(1) Y325-111
(2) 94645
(2) 94622
(4) - - - - -
(2) 94628
(2) 94624
(8) 94628
(1) 92956-1
(1) 66885-1
(1) 94626
(1) 94625
(16) 93886
(1) Y17-13-S
[Mtl] Part No. [Mtl]
ꢀ
1
2
5
6
Connecting Rod
[SS] 93084
[SS]
[B]
[GFN]
[SS]
[A]
[SS]
[A]
[SS]
[SS]
(3/32” x 5/8” o.d.)
“O” Ring
[B] Y325-111
[GFN] 94645
[SS] 94622
- - - 95092
[SS] 94628
[SS] 95064
[SS] 94628
[SS] 92956-1
66885-1
(2” o.d.)
(2” o.d.)
Diaphragm Washer
Diaphragm Washer
ꢀ
12 Washer
14 Bolt
15 Fluid Cap
26 Bolt
(5/16” - 18 x 3/4”)
(5/16” - 18 x 3/4”)
43 Ground Strap
57 Ground Kit Assembly
(not shown)
(bottom)
60 Inlet Manifold
[SS] 95065
[SS] 95066
[SS] 93886
[SS] Y227-5-L
[A]
[A]
[SS]
[C]
(top)
61 Outlet Manifold
(5/16” - 18)
62 Flange Nut
63 Pipe Plug
(1/2 - 14 N.P.T.)
“Smart Parts”, keep these items on hand in addition to the service kit for fast repair and reduction of down time.
†
Viton® is registered trademark of the DuPont Company Flouraz® is a registered trademark of Greene, Tweed and Company
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ARO® is a registered trademark of Ingersoll-Rand Company Santoprene® is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P.
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Loctite® is a registered trademark of Henkel Loctite Corporation 271™ is a trademark of Henkel Loctite Corporation
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Page 4 of 8
PD05P-XXX-XXX (en)
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PARTS LIST / PD05P-XXX-XXX FLUID SECTION
COLOR CODE
Diaphragm
Color
3
1
Ball
Color
Material
Nitrile
Santoprene
PTFE
Black
Tan
White
Red (
Tan
White
)
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5
7
8
6
Viton
Yellow (
)
y
Yellow (
)
y
( ) Dot
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61 (models PD05P-AAS-XXX)
2
4
ꢁ
Torque SequencePTFE
26 ꢁꢂ
61 (models PD05P-ASS-XXX)
FOR THE AIR MO-
TOR SECTION, SEE
PAGES 6 & 7.
ꢀ
2
1
ꢀ
5
7
6
14 ꢁꢅ
22
12
21
19
ꢃ
ꢀ
62 ꢁꢂ
15
43
22
26 ꢁꢂ
60 (models PD05P-ASS-XXX)
63
12
21
19
ꢃ
ꢀ
ꢄ
60 (models PD05P-AAS-XXX)
Figure 3
Santoprene - 8
air side (tan)
PTFE - 7
fluid side (white)
View for PD05P-AXS-XXT (PTFE dia-
phragm) configuration only.
LUBRICATION / SEALANTS
Apply Key-Lube to all “O” rings, “U” cups and mating parts.
Apply pipe sealant to threads.
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e
TORQUE REQUIREMENTS
)
(
Apply anti-seize compound to threads and bolt and nut flange
heads which contact pump case when using stainless steel
fasteners.
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.
(62) Nut, 50 - 60 in. lbs (5.6 - 6.8 Nm), / alternately and evenly, then
re-torque after initial run-in.
Apply Loctite® 271™ to threads.
f
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Used on models PD05P-AAS-XXX only.
PD05P-XXX-XXX (en)
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PARTS LIST / PD05P-XXX-XXX AIR MOTOR SECTION
Indicates parts included in 637141 air section repair kit.
9
AIR MOTOR PARTS LIST
(size)
(size)
Item Description
101 Motor Body
(Qty) Part No.
(1) 93091
(2) Y325-117
(1) 93087
(2) 37285
(1) 93085
(1) 93088
(4) 93075
(3) 115959
(2) 77802
(1) 66972
(1) 93092
(1) 93107
(16) 93095
(1) 93339-1
[Mtl]
Item Description
(Qty) Part No.
(4) 93096
(4) Y6-419-T
(1) 93090
(1) 93086
(1) Y325-125
(1) 94395
(1) 96383
(1) 93276
(1) 93275
(2) 116038
(2) 93089
(1) 93110
(1) 93706-1
637175
[Mtl]
[SS]
[SS]
[P]
(9/32” i.d.)
[P]
133 Washer
(3/32” x 1” o.d.)
(1/4” - 20 x 5”)
134 Bolt
102 “O” Ring
103 Sleeve
[B]
9
ꢀ
ꢀ
[Bz]
[C]
135 Valve Block
136 Plug
(13/16”)
104 Snap Ring
111 Spool
[D]
(3/32” x 1-1/2” o.d.)
[D]
[C]
137 “O” Ring
[B]
9
9
9
9
9
(1/8” x 1” o.d.)
118 Piston
138 “U” Cup Packing
139 “U” Cup Packing
140 Valve Insert
141 Valve Plate
142 Washer
[U]
(1/8” x 3/4” o.d.)
(1/8” x 1-7/16” o.d.)
119 “O” Ring
120 Spacer
[U]
[Z]
[U]
9
ꢀ
9
[Ck]
[Ck]
[Z]
(1/2”)
122 Snap Ring
129 Muffler
[C]
[P]
(optional)
129 Exhaust Cover
130 Gasket
[PS]
[SY]
[SS]
[B]
143 Plate
[SS]
[C]
(optional)
201 Muffler
9
9
(5/16 - 18 x 1-1/4”)
131 Bolt
Key-Lube, “O” Ring Lubricant
Key-Lube, 10 Pack
9
132 Gasket
“Smart Parts”, keep these items on hand in addition to the service kit for
fast repair and reduction of down time.
NOTE 1: A major valve service assembly is available separately which in-
cludes items 111, 132, 135 - 141. Order part number 66362.
†
MATERIAL CODE
FLUID SECTION REASSEMBLY
Reassemble in reverse order.
Lubricate (1) connecting rod and (2) “O” ring with Key-
Lube “O”ring lube.
[B]
[Bz]
[C]
=
=
=
=
Nitrile
Bronze
Carbon Steel
Ceramic
[D]
[P]
=
=
Acetal
Polypropylene
[SY] = Syn-Seal
[U] = Polyurethane
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[PS] = Polyester
[SS] = Stainless Steel
[Z]
=
Zinc
[Ck]
Install (5) washers with i.d. chamfer toward diaphragm.
When replacing PTFE diaphragms, install the 93465 San-
toprene diaphragm behind the PTFE diaphragm.
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DIAPHRAGM PUMP SERVICE
GENERAL SERVICE NOTES:
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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AIR MOTOR SECTION SERVICE
Service is divided into two parts - 1. Pilot Valve, 2. Major
Tools needed to complete disassembly and repair:
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Valve.
1/2” socket or wrench, 7/16” socket or wrench, torque
wrench (measuring inch pounds), “O”ring pick.
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Air Motor Section service is continued from Fluid Section
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repair.
FLUID SECTION DISASSEMBLY
1. Remove (61) top manifold.
2. Remove (19) “O” rings, (21) seats, (12) washers (where ap-
plicable) and (22) balls.
3. Remove (60) bottom manifold.
4. Remove (19) “O” rings, (21) seats, (12) washers (where ap-
plicable) and (22) balls.
5. Remove (15) fluid caps.
PILOT VALVE DISASSEMBLY
1. Remove (122 and 104) snap rings.
2. Remove (143) plates.
3. Remove (103) sleeve and (102) “O”rings.
4. Remove (118) piston, (142) washers, (119) “O” rings and
(120) spacers from (101) motor body.
6. Remove (14) bolt, (6) diaphragm washer, (7) or (7 / 8) dia-
phragms and (5) washer.
7. Remove (1) connecting rod from air motor.
8. 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.
9. Remove (2) “O”ring from connecting rod.
PILOT VALVE REASSEMBLY
1. Assemble (119) "O" rings, (120) spacers and (142) washers
on (118) piston.
2. Insert the stack into the (101) body. (103) sleeve may be
used to assist pressing stack into body.
3. Install (103) sleeve and (102) "O" rings into (101) body.
4. Install (143) plates and (122 and 104) snap rings.
Page 6 of 8
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PARTS LIST / PD05P-XXX-XXX AIR MOTOR SECTION
(optional) 201
(optional) 129
131
101
103
ꢀ 102
140
141
132
MAJOR VALVE
(see note 1, page 6)
133
130
129
104
135
ꢆ 134
138
ꢀ
120
143
111
136
139
137
ꢀ
ꢀ
118
142
119
PILOT VALVE
ꢀ
142
122
) TORQUE REQUIREMENTS (
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(134) Torque to 15 - 20 in. lbs (1.7 - 2.3 Nm), wait 10 minutes, then
re-torque to 15 - 20 in. lbs (1.7 - 2.3 Nm).
Figure 4
LUBRICATION / SEALANTS
c
Apply Key-Lube to all “O” rings, “U” cups and mating parts.
MAJOR VALVE DISASSEMBLY
MAJOR VALVE REASSEMBLY
1. Remove (129) muffler and (130) gasket.
1. Assemble new (138 and 139) “U” cups on (111) spool -
2. Pull (135) valve block assembly from (101) motor body.
LIPS MUST FACE EACH OTHER.
3. Remove (134) bolts, (133) washers and (132) gasket from
(135) valve block.
4. Remove (141) valve plate and (140) valve insert.
5. Remove (136) plug and (111) spool.
2. Insert (111) spool into (135) valve block.
3. Assemble (137)“O”ring on (106) plug and insert into (135)
valve block.
4. 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 2 identification dots toward (132) gasket.
5. Assemble (132) gasket, (135) valve block and (129) muf-
fler assembly to (101) motor body, securing with (134)
bolts. NOTE: Tighten (134) bolts to 15 - 20 in. lbs (1.7 - 2.3
Nm).
PD05P-XXX-XXX (en)
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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
1/2” minimum or larger if high viscosity fluids are being
pumped. Suction hose must be non-collapsible type, ca-
pable 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.
Check for sticking or improperly seating check valves.
If pump cycles at a high rate or runs erratically, check (119)
piston “O”rings for wear.
y
Check “U”cups on (111) spool in major valve.
Check (141) valve plate and (140) insert for wear.
Check (103) sleeve and (2) “O” ring on diaphragm con-
necting rod.
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Check (119) “O”rings on (118) piston for wear.
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DIMENSIONAL DATA
Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
(Material Outlet)
(Air Inlet)
N
M
E
F
A
G
B
D
H
K
J
C
L
Figure 5
(Material Inlet)
N
DIMENSIONS
F - 6” (152.4 mm)
G - 11-5/8” (295.3 mm)
H - 4-7/8” (123.8 mm)
J - 5-1/2" (139.7 mm)
A - 7-11/16”(195.3 mm)
B - 11-1/32”(280.2 mm)
C - 6-1/8”(155.6 mm)
D - 2”(50.8 mm)
K - 5/16” (7.9 mm)
L - 8-1/4” (209.6 mm)
M - 1/4 - 18 P.T.F. SAE short
N - 1/2 - 14 N.P.T.F. - 1
E - 6-7/16” (163.6 mm)
PN 97999-781
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