Ingersoll Rand Water Pump PH10A X X User Manual

PH10A-X-X  
OPERATOR’S MANUAL  
RELEASED:  
REVISED:  
7-7-00  
INCLUDING: OPERATION, INSTALLATION & SERVICE  
10-15-10  
1” HIGH PRESSURE DIAPHRAGM PUMP(REV. M)  
3:1 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 material options.  
637338 for air section repair (see page 6).  
637339 for fluid section repair (models PH10A-XXX-XSX)(see page 4).  
637339-1 for fluid section repair (models PH10A-XXX-XHX)(see page 4).  
PUMP DATA  
Models . . . . . . . . . . . see “Model Description Chart” for “-XXX”.  
Pump Type . . . . . . . . Metallic Air Operated, High Pressure,  
Double Diaphragm.  
Material . . . . . . . . . . . see “Model Description Chart”.  
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 94.73 lbs (42.97 kg)  
Maximum Air Inlet Pressure . . . . . . . . . 100 p.s.i. (6.9 bar)  
Maximum Outlet Pressure . . . . . . . . . . 300 p.s.i. (20.4 bar)  
Maximum Flow Rate (flooded inlet) . . . 26 g.p.m. (98.4 l.p.m.)  
Maximum Particle Size . . . . . . . . . . . . 1/8” dia. (3.2 mm)  
Maximum Temperature Limits (diaphragm / ball / seal material)  
Nitrile . . . . . . . . . . . . . . . . . 10_ to 180_ F (-12_ to 82_ C)  
PTFE . . . . . . . . . . . . . . . . . 40_ to 225_ F (4_ to 107_ C)  
Displacement / Cycle @ 100 p.s.i. . . . . 0.06 gal. (0.23 lit.)  
Dimensional Data . . . . . . . . . . . . . . . . see page 8.  
Noise Level @ 70 p.s.i., 60 c.p.m. . . . . . 84.5 db(A)j  
PH10A-XSS-XXT  
1” DIAPHRAGM PUMP  
Figure 1  
MODEL DESCRIPTION CHART  
j
The pump sound pressure levels published here have been updated to an Equivalent Continuous  
SoundLevel(L )tomeettheintentofANSIS1.13-1971,CAGI-PNEUROPS5.1usingfourmicro-  
Aeq  
phone locations.  
PH10 A - X S S - X X T  
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.  
Center Section Material  
A - Aluminum  
Fluid Connection  
A - 1 - 11-1/2 N.P.T.F. - 1  
B - Rp 1 (1 - 11 BSP parallel)  
Fluid Caps & Manifold Material  
S - Stainless Steel  
Hardware Material  
S - Stainless Steel  
Seat Material  
H - Hard 440 Stainless Steel  
S - 316 Stainless Steel  
Ball Material  
H - Hard 440 Stainless Steel  
S - 316 Stainless Steel  
Diaphragm Material  
T PTFE  
INGERSOLL RAND COMPANY LTD  
209 NORTH MAIN STREET -- BRYAN, OHIO 43506  
(800) 276-4658 D FAX (800) 266-7016  
E2010  
CCN 99755480  
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START-UP  
GENERAL DESCRIPTION  
1. Turn pressure control knob until motor starts to cycle.  
2. Allow pump tocycleslowlyuntilit isprimedandallair ispurgedfrom  
the fluid hose or dispensing valve.  
The1” metallicdiaphragm pumpoffershighvolumedeliveryeven atlow  
airpressures,easyselfpriming,theabilitytopumpvariousviscosityma-  
terials and the ability to pass solids (as stated in the chart above). The  
pump is offered with optional wetted parts configurations to satisfy a va-  
rietyofapplicationrequirements.RefertotheModelDescriptionChart”.  
3. Turn off dispensing valve and allow pump to stall - check all fittings  
for leakage.  
4. Adjust the regulator as required to obtain desired operating pres-  
sure and flow.  
AIR AND LUBE REQUIREMENTS  
SHUTDOWN  
S Itisgoodpracticetoperiodicallyflushentirepumpsystemwithasol-  
vent that is compatible with the material being pumped, especially if  
the material being pumped is subject to “settling-out” when not in  
use for a period of time.  
WARNING EXCESSIVE AIR PRESSURE. Can cause person-  
al injury, pump damage or property damage. Do not exceed  
maximum inlet air pressure as stated on pump.  
S Afiltercapableoffilteringoutparticleslargerthan50micronsshould  
beusedontheairsupply. Thereisnolubricationrequiredotherthan  
the “O” ring lubricant which is applied during assembly or repair.  
S Iflubricatedairispresent,makesurethatitiscompatiblewiththeO”  
rings and seals in the air motor section of the pump.  
S Disconnecttheairsupplyfromthepumpifitistobeinactiveforafew  
hours.  
SERVICE  
S Certain ARO “Smart Parts” are indicated which should be available  
for fast repair and reduction of down time.  
TRANSPORT AND STORAGE  
S Provide a clean work surface to protect sensitive internal moving  
partsfromcontaminationfromdirtandforeignmatter duringservice  
disassembly and reassembly.  
S Storeinadryplace, donotremoveproductfromboxduringstorage.  
S Do not remove protection caps from inlet and outlet prior to installa-  
tion.  
S Keep good records of service activity and include pump in preven-  
tive maintenance program.  
S Do not drop or damage box, handle with care.  
S USEONLYGENUINEARO REPLACEMENT PARTSTOASSURE  
PERFORMANCE AND PRESSURE RATING.  
INSTALLATION  
S Contact your local authorized ARO Service Center for parts and  
customer service information.  
S Secure the diaphragm pump legs to a suitable surface to insure  
against damage by excessive vibration.  
S Pumpcyclerate andoperatingpressureshouldbecontrolledbyus-  
ing an air regulator on the air supply.  
S ServiceKitsare availabletoservicetwo separateDiaphragmPump  
functions: 1. AIR SECTION, 2. FLUID SECTION. The Fluid Section  
is divided further to match typical active MATERIAL OPTIONS.  
S Theoutletmaterialvolumeisgovernednotonlybytheairsupplybut  
alsobythematerialsupplyavailableattheinlet.Thematerialsupply  
tubing should not be too small or restrictive. Be sure not to use hose  
which might collapse.  
FLUID SECTION SERVICE  
GENERAL SERVICE NOTES:  
S Use flexible connections (such as hose) at the suction and dis-  
charge, these connections should not be rigid piped and must be  
compatible with the material being pumped.  
S Clean and inspect each part thoroughly upon disassembly, look for  
deep scratches on metallic surfaces and nicks, cuts or flat spots on  
“O” rings. Replace any of the parts that are of questionable condi-  
tion.  
S Install a ground wire where applicable.  
S Upondisassembly,lookforanyremnantsofOringsintheairmotor  
valve areas.  
S Tools required: 3/16” Allen wrench, 3/8” Allen wrench, 4 mm Allen  
wrench,6mmAllenwrench,7/16wrench/socket,1/2wrench,3/4”  
wrench/socket,7/8wrench/socket,2-1/2wrench,13mmwrench  
/ socket, “O” ring pick, plastic mallet and spanner wrench.  
OPERATING INSTRUCTIONS  
NOTICE  
Check the tightness of the (29) tie rod nuts after  
first run in period due to possible compression set of the dia-  
phragm. If retorquing is required, be sure all pressure has been re-  
lieved from the pump and supply lines. Loosen (26) cap screws.  
Retorque(29)flangenutsto280-300in. lbs(31.6-33.9Nm).Tight-  
en (26) cap screws to 120 - 140 in. lbs (13.6 - 15.8 Nm).  
S Always flush the pump with a solvent compatible with the material  
beingpumpedifthematerialbeing pumpedissubjectto “settingup”  
when not in use for a period of time.  
S Disconnecttheairsupplyfromthepumpifitistobeinactiveforafew  
hours.  
S LoctiteR is a registered trademark of Henkel Loctite Corporation S AROR is a registered trademark of Ingersoll-Rand Company S  
S 271t and 572t are trademarks of Henkel Loctite Corporation S  
PH10A-XXX-XXX (en)  
Page 3 of 8  
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PARTS LIST / PH10A-XXX-XXX FLUID SECTION  
assembly, (150) “O” ring and (149) adapter piston. Do not disas-  
FLUID SECTION PARTS  
semble further unless damage is evident.  
Item Description (size)  
Qty Part No.  
[Mtl]  
12. Using an “O” ring pick, remove the (165) quad ring and two (164)  
back-up rings from the (163) bushing.  
L
Fluid Section Service Kit  
637339-( )  
S SERVICE NOTE: Removal of the (163) bushing should not be nec-  
essary,howeveritmustbecheckedforsharpedgesandremovedto  
prevent possible further damage.  
V 1 Rod  
(1) 98724-1  
(1) Y330-113  
(4) Y328-112  
(2) 94074-1  
(2) 94055  
[C]  
[B]  
n 2 “O” Ring (3/32” x 3/4” o.d.)  
L 3 “O” Ring (3/32” x 11/16” o.d.)  
V 5 Plate  
[T]  
[C]  
FLUID SECTION REASSEMBLY  
V 6 Diaphragm Plate  
L 7 Diaphragm  
[SS]  
[T]  
S Clean all parts upon reassembly. Lubricate all replacement parts  
and metallic moving parts with Key-Lube grease upon reassembly.  
S SERVICE NOTE: PTFE “O” rings are not resilient and they should  
always be replaced with new ones.  
1. Install the (164) back-up ring by pulling it apart, twist or walk it down  
into the cavity bottom inside the (163) bushing.  
2. Install the (165) quad ring on top of the spiral ring by folding it in half  
allowing it to get past the bushing i.d. and into the cavity.  
3. Install the second (164) back-up ring as in step 1. Locate it on top of  
the quad ring. Lubricate and smooth out the set with your finger to  
assure good alignment.  
4. Placethe(9) washer onto the(14) bolt, with thechamfer againstthe  
bolt head, place the (3) “O” ring onto the (14) bolt and insert these  
three parts thru the (6) plate.  
5. Place the (7) diaphragm onto this assembly, (see assembly note,  
page 5).  
6. Assemble the (150) “O” ring and (148) piston assembly to the (149)  
adapter piston, securing with the (151) nut.  
7. Lubricate the (152) cylinder wall and insert the piston assembly into  
the cylinder and through the bushing / quad seal.  
8. ApplyLoctiteR#271ttotheinnerthreadsofthe(149)adapterpis-  
ton.  
9. Placethe(3)Oringontheendofthe(149)adapterpistonandslide  
the (5) plate over it.  
10. Thread the piston assembly and diaphragm assembly together.  
Hold the piston assembly with a spanner wrench, align the dia-  
phragm with the bolt holes and torque the (14) bolt to 49 - 52 ft lbs  
(66.4 - 70.5 Nm).  
(2) 94800  
9
Washer (1.375” o.d. x 0.505” i.d.)  
(2) 93189-1  
(2) Y5-87-T  
(2) 95191  
[SS]  
[SS]  
[SS]  
[T]  
14 Bolt (1/2” - 20 x 1-1/2”)  
15 Fluid Cap  
L 19 “O” Ring (3/32” x 1-9/16” o.d.)  
L 21 Seat (PH10A-XSS-SXT)  
(PH10A-XSS-HXT)  
(4) Y328-126  
(4) 90428  
[SS]  
[SH]  
[SS]  
[SH]  
[SS]  
[C]  
(4) 93367-1  
(4) 90948  
L 22 Ball (1” dia.) (PH10A-XSS-XST)  
(PH10A-XSS-XHT)  
(4) Y16-132  
(8) 95177  
26 Cap Screw (M8 x 1.25 x 25 mm)  
29 Flange Nut (M8 x 1.25)  
32 Bracket, Right Side  
Bracket, Left Side  
(16) 95535  
(2) 94154-1  
(2) 94154-2  
(2) 94394  
[C]  
[C]  
V 36 Manifold (PH10A-ASS-XXT - N.P.T.F.)  
(PH10A-BSS-XXT - BSP)  
[SS]  
[SS]  
[Co]  
[SS]  
(2) 94394-1  
(1) 93004  
43 Ground Lug  
67 Screw (1/4” - 20 x 5/8”)  
(1) 93860  
V “Smart Parts”, keep these items on hand in addition to the service kits for fast repair  
and reduction of down time.  
n Indicates parts included in 637338 air section service kit.  
MATERIAL CODE  
[Co] = Copper  
[B] = Nitrile  
[C] = Carbon Steel  
[SS] =Stainless Steel  
[T] = PTFE  
[SH] = Hard Stainless Steel  
11. Install the (159) “O” ring and the (153) large “O” ring. Assemblyhint:  
A liberal amount of Key-Lube grease will hold these in place tempo-  
rarily.  
12. Align the (154 or 155) auxiliary body with the (125) dowel pin and  
(158) cap screws, and push together, securing with two (158) cap  
screws.  
S CAUTION: The tie rods can tear the diaphragm and ruin it. Hold the  
diaphragm against the pump body with your fingers when pushing  
each rod end through.  
FLUID SECTION DISASSEMBLY  
ThefollowingprocedureisfortheinstallationofFluidSectionServiceKit  
parts. Refer to the view on page 5. The items with three digits are on  
pages 5, 6 and 7.  
The steps shown below are for one side, repeat the steps 7 thru 12 to  
service the other side.  
1. Remove four (26) cap screws, releasing (36) top manifold.  
2. Remove (22) balls, (19) “O” rings and (21) seats.  
3. Remove four (26) cap screws, releasing (36) bottom manifold.  
4. Remove (19) “O” rings, (21) seats and (22) balls.  
5. Remove eight (29) nuts, releasing (32) brackets.  
6. Remove one (15) fluid cap.  
7. Usingaplasticmallet, tapthe(124) tierodsbackflushinto the auxil-  
iary body.  
8. Removetwo(158)capscrews,releasing(154or155)auxiliarybody  
and diaphragm assembly.  
9. Remove (159) “O” ring and one (153) “O” ring.  
S SERVICENOTE:Thenextfewstepsrelateonlytodiaphragmdisas-  
sembly. Further disassemblywouldnot normallyberequiredunless  
thereisdamage/wearfoundonthe(148)pistonoronthefaceofthe  
(152) cylinder.  
10. Using a spanner wrench to hold the (149) adapter piston and a 3/4”  
socket on the (14) bolt, remove the (14) bolt, releasing (9) washer, (3)  
“Oring, (6)diaphragmplate, (7)diaphragm, (5)plateand(3) “Oring.  
11. Removethepistonassemblyandinspectthe(151)nut, (148)piston  
13. Align the diaphragm with the proper holes in the body and push the  
rodsthroughfarenoughtoallowinstallationofthe(15)fluidcaps.Be  
certain the flow direction is oriented correctly.  
14. Assemble four (29) nuts.  
15. Install two (32) brackets, securing with four (29) nuts.  
S NOTE: Tighten the fluid cap nuts in a cross pattern alternately and  
evenly. Torque (29) nuts to 280 - 300 in. lbs (31.6 - 33.9 Nm).  
16. Assemble (22) balls, (21) seats and (19) “O” rings into the cavity in  
the bottom of (15) fluid caps.  
17. Assemble (36) bottom manifold to fluid caps, securing with (26) cap  
screws. NOTE: Torque (26) cap screws to 120 - 140 in. lbs (13.6 -  
15.8 Nm).  
18. Assemble (21) seats, (19) “O” rings and (22) balls into the cavity in  
the top of (15) fluid caps.  
19. Assemble (36) top manifold to fluid caps, securing with (26) cap  
screws. NOTE: Torque (26) cap screws to 120 - 140 in. lbs (13.6 -  
15.8 Nm).  
Page 4 of 8  
PH10A-XXX-XXX (en)  
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PARTS LIST / PH10A-XXX-XXX FLUID SECTION  
3
2
1
4
36  
5
7
8
6
26 , m  
FOR THE AIR MOTOR SECTION  
SEE PAGES 6 & 7  
158 m  
Torque Sequence  
2 j  
155  
125  
1
124  
159 j  
149  
150 j  
148  
151  
153 j  
152  
153 j  
164  
165 j  
163  
Largest convolusion (ripple) this side.  
154  
3 j  
5
7 o  
6
3 j  
9 n  
14 , l  
22  
19 j  
21  
125  
j 159  
k 126  
. TORQUE REQUIREMENTS ,  
NOTE: DO NOT OVERTIGHTEN FASTENERS.  
15  
(14) Bolt, 49 - 52 ft lbs (66.4 - 70.5 Nm).  
(26) Bolts, 120 - 140 in. lbs (13.6 - 15.8 Nm).  
(29) Flange nuts, 280 - 300 in. lbs (31.6 - 33.9 Nm) tighten alternately and evenly.  
m . 29  
32  
LUBRICATION / SEALANTS  
j
Apply Key-Lube grease (93706-1) to all “O” rings, “U” cups and mating parts.  
k Apply Loctite 572t to threads at assembly.  
67  
l
Apply Loctite 271 to threads at assembly.  
m Apply anti-sieze compound to threads and bolt and nut flange heads which  
contact pump case when using stainless steel fasteners.  
43  
ASSEMBLY NOTES  
n Assemble with i.d. chamfer against bolt head.  
o Assemble with largest convolusion (ripple) towards (6) diaphragm plate.  
Figure 2  
PH10A-XXX-XXX (en)  
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PARTS LIST / PH10A-XXX-XXX AIR MOTOR SECTION  
n Indicates parts included in 637338 Air Section Repair Kit.  
Item Description (size)  
101 Motor Center Body  
n 102 “O” Ring (1/16” x 1” o.d.)  
V 103 Sleeve  
Qty Part No.  
(1) 95122-1  
(2) Y325-20  
(1) 94527  
(2) 95125  
(1) 92011  
Mtl  
[A]  
[B]  
[D]  
[SS]  
[D]  
[B]  
[A]  
[Z]  
Item Description (size)  
n 150 “O” Ring (1/16” x 1-3/16” o.d.)  
V 151 Nut  
Qty Part No.  
(2) Y325-23  
(2) 94072  
Mtl  
[B]  
[C]  
[Fg]  
[B]  
[A]  
[A]  
[SS]  
[B]  
[Bz]  
[T]  
152 Cylinder  
(2) 94801  
104 Plate  
nL153 “O” Ring (1/8” x 6-1/2” o.d.)  
154 Auxiliary Body - Right  
155 Auxiliary Body - Left  
158 Cap Screw (M8 x 1.25 x 25 mm)  
n 159 “O” Ring (1/16” x 7/16” o.d.)  
163 Bushing  
(6)j Y325-259  
(1) 94750-1  
(1) 94751-1  
(4) 95177  
109 Piston  
n 110 “U” Cup (3/16” x 1-3/8” o.d.)  
111 Spool  
(1) Y186-51  
(1) 92005  
(5) 92877  
(5) Y325-214  
(6) Y325-126  
(4) 92876  
(1) 92006  
(2) 95126  
(2) 95123  
(4) 95176  
(8) 95195  
(2) Y148-45  
(10) Y227-2-L  
(1) 94763  
(2) 94075  
(2) Y325-31  
(2) 61419  
(2) 94073-1  
112 Washer (1.556” o.d.)  
n 113 “O” Ring (small) (1/8” x 1-1/4” o.d.)  
n 114 “O” Ring (large) (3/32” x 1-9/16” o.d.)  
115 Spacer  
(2) Y325-11  
(2) 94053  
[B]  
[B]  
[Z]  
nL164 Back-Up Ring (3/4” i.d. x 1” o.d.)  
nL165 Quad Ring  
(4) Y118-210  
(2) 94050  
[B]  
[D]  
[U]  
[B]  
[Br]  
[B]  
[B]  
[B]  
[B]  
[C]  
116 Spacer  
[Z]  
n 167 Pilot Piston (includes 168 and 169)  
168 “O” Ring (3/32” x 5/8” o.d.)  
169 “U” Cup (1/8” x 7/8” o.d.)  
170 Piston Sleeve  
(1) 67164  
V 118 Actuator Pin  
V 121 Plug  
[SS]  
[D]  
[C]  
[SH]  
[C]  
[C]  
[Br]  
[SS]  
[B]  
[B]  
[C]  
(2) 94433  
(1) Y240-9  
(1) 94081  
123 Button Head Screw (M6 x 1 x 12 mm)  
124 Tie Rod  
n 171 “O” Ring (3/32” x 1-1/8” o.d.)  
n 172 “O” Ring (1/16” x 1-1/8” o.d.)  
n 173 “O” Ring (3/32” x 1-3/8” o.d.)  
n 174 “U” Cup (1/8” x 1/2” o.d.)  
201 Muffler  
(1) Y325-119  
(1) Y325-22  
(2) Y325-123  
(2) Y186-43  
(1) 93110  
125 Dowel Pin (5/16” o.d. x 5/8”)  
126 Pipe Plug (1/8 - 27 N.P.T.)  
127 Street Elbow  
136 Plug  
n 137 “O” Ring (1/16” x 1-7/8” o.d.)  
148 Piston Assembly  
149 Adapter Piston  
n L Key-Lube “O” Ring Lubricant  
(1) 93706-1  
637175  
10 Pack Key-Lube Grease  
V “Smart Parts”, keep these items on hand in addition to the service kits for fast repair and reduction of down time.  
L Indicates parts included in 637339--( ) fluid section service kit.  
2. A light tap on (118) actuator pin should expose the opposite (121)  
MATERIAL CODE  
plug and (167) pilot piston.  
[A] = Aluminum  
[B] = Nitrile  
[Br] = Brass  
[Bz] = Bronze  
[C] = Carbon Steel  
[SS] = Stainless Steel  
[T] = PTFE  
[U] = Polyurethane  
[Z] = Zinc  
[D] = Acetal  
3. Remove(170) pistonsleeveand inspectthe inner bore for damage.  
[Fg] = Fiberglas  
[SH] = Hard Stainless Steel  
PILOT VALVE REASSEMBLY  
AIR SECTION SERVICE  
S Lubricateallsoft parts, spool andbores withKey-Lube greaseupon  
reassembly.  
1. Assemble the trailing (102) “O” ring to (103) sleeve and assemble  
sleeve into motor center body, pushing thru far enough to expose  
“O” ring groove on opposite end.  
2. Assemble(102)Oringto(103)sleeveandpushsleeveontomotor  
center body.  
3. Assemble (2) “O” ring to (1) rod and assemble into (103) sleeve.  
4. Assemble (171 and 172) “O” rings to (170) piston sleeve and as-  
semble into (101) center body. NOTE: Assemble sleeve with small  
i.d. into center body.  
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.  
GENERAL SERVICE NOTES:  
S Air Motor Section Service is continued from step 8 of the Fluid Sec-  
tion Disassembly.  
S It is not necessary to remove the Fluid Section Ends to gain access  
to the Air Motor Major Valve Section.  
S In most cases, problems of an air control nature will reside in the Air  
Valve area.  
S Removal of the Fluid Sections is required to install all of the parts in-  
cluded inthe AirSection ServiceKit, ifthisisthe case, follow steps1  
thru8oftheFluidSectionDisassemblyonbothsidesandisolatethe  
Air Section.  
5. Assemble two (168) “O” rings and (169) “U” cup to (167) pilot piston  
(note the lip direction of “U” cup) and assemble into (170) piston  
sleeve.  
S
j SERVICEKIT NOTE:OnlytworeplacementOringsaresupplied  
in the 637338 and 637339-( ) kits.  
6. Assemble (173) “O” rings and (174) “U” cups (note lip direction) to  
(121) plugs.  
7. Assemble (118) actuator pins to (121) plugs and assemble (121)  
plugs into (101) center body.  
PILOT VALVE DISASSEMBLY  
8. Assemble (104) plates to (101) center body, securing with (123)  
screws.  
S NOTE: Both outer pump Fluid Sections must be removed to access  
the Pilot Section parts (see figure 3, page 7).  
1. Remove two (123) screws and (104) plate from both sides of the  
(101) motor center body.  
9. Reassemble fluid section parts.  
Page 6 of 8  
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PARTS LIST / PH10A-XXX-XXX AIR MOTOR SECTION  
IMPORTANT  
LUBRICATION / SEALANTS  
Apply Key-Lube grease (93706-1)  
to all “O” rings, “U” Cups & mat-  
ing parts.  
BE CERTAIN TO ORIENT (115) SPACER LEGS  
AWAY FROM BLOCKING INTERNAL PORTS  
WHEN REASSEMBLING AIR SECTION.  
j
MAJOR VALVE  
See cross section detail figure 4.  
136  
j 137  
k
l
Apply Loctite 271 to threads.  
Apply Loctite 572 to threads.  
j 111  
m Refer to steps 1 and 2 of “Pilot  
116  
Valve Reassembly”.  
115  
j 114  
j 113  
112  
MAJOR VALVE  
CROSS SECTION DETAIL  
j
j
j
j
109  
111 112  
115 116  
110  
114 113  
201  
l 126  
127  
101  
123 k  
104  
174 j  
173 j  
169 j  
Figure 4  
102 jm  
103  
102 jm  
121  
118  
167  
j 168  
104  
170  
j 172  
j 171  
123 k  
118  
173 j  
121  
PILOT  
VALVE  
174 j  
110 j  
137 j  
109  
126 l  
136  
Figure 3  
ward, follow it with the larger (114) “O” ring.  
MAJOR VALVE DISASSEMBLY  
2. Place (113) “O” ring on the (115) spacer, insert the spacer with the  
legs facing outward, be sure not to block the internal ports with the  
spacerlegs.Repeatthisprocessthreetimesandmakecertaineach  
set is pressed in well.  
1. Remove the two (124) tie rods blocking the (136) plugs.  
2. Using a 3/8” Allen wrench, remove both (136) plugs. Check the  
(137) “O” rings and make certain they are intact and undamaged.  
Fragments of “O” rings can cause the pump to malfunction.  
3. Install the last (112) washer and a(114) “O” ring, placethe last(113)  
“O” ring onthe(116) spacer andinstall. Installthe last(114) “Oring.  
4. Lubricate the (111) spool and install (this is the side opposite of the  
air inlet). Note: The end with the hole in it faces outward.  
5. Install a new (137) “O” ring on the (136) plug and thread it into the  
(101 motor center body.  
S Note: Align plug carefully and take care not to damage “O” rings.  
6. Assemble the (110) “U” cup to the (109) piston and install it into the  
air inlet side with the lips facing outward.  
7. Install new (137) “O” ring on the (136) plug and install into the (101)  
motor center body.  
8. Assemble(124)tierods,securingwith(29)nuts.NOTE:Torque(29)  
nuts to 280 - 300 in. lbs (31.6 - 33.9 Nm).  
3. Fromtheairinletside(usealargedowelandsoftmallet) tapmoder-  
atelyonthe(109)pistonandthenpushtheentirevalvestackoutthe  
opposite side. Clean and inspect all parts for damage and wear.  
MAJOR VALVE REASSEMBLY  
S Lubricateallsoftparts,spool,andboreswithKey-Lubegreaseupon  
reassembly.  
1. For best results, rebuild the Major Valve stack one piece at a time.  
Start with the (112) washer and install it in the side opposite the air  
inlet. Place the washer into the bore with the raised edge facingout-  
PH10A-XXX-XXX (en)  
Page 7 of 8  
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TROUBLE SHOOTING  
Product discharged from exhaust outlet.  
S Check for diaphragm rupture.  
S Check tightness of bolt (14).  
S Do not use air line additives containing solvents.  
S Do not spray pump off with solvents, wipe clean only.  
S Check “O” rings on (111) spool in major valve.  
S Check (103) sleeve and (2) “O” ring on (1) rod.  
S Check (168) “O” rings on (167) pilot piston for wear.  
Air bubbles in product discharge.  
S Check connections of suction plumbing.  
S Check “O” rings between intake manifold and fluid caps.  
S Check tightness of bolt (14).  
Low output volume.  
S Check air supply.  
S Check for plugged outlet hose.  
Pump blows air out main exhaust when stalled on either stroke, a  
typical cause of pump malfunction can be attributed to problems  
with “O” rings.  
S For the pump to prime itself, it must be mounted in the vertical posi-  
tion so that the balls will check by gravity.  
S Check for pump cavitation -- suction pipe should be 1” minimum or  
larger if high viscosity fluids are being pumped. Suction hose must  
be non-collapsible type, capable of pulling a high vacuum.  
S Checkalljointsonintakemanifoldsandsuctionconnections. These  
must be airtight.  
S Check for sticking or improperly seating check valves.  
S Ifpumpcyclesatahighrateorrunserratically, check(168)Orings  
for wear.  
S Segments of broken “O” rings can move around or lodge in areas of  
the air motor valve section.  
S Swollen “O” rings can cause valve parts to stick or seize. Solvents  
can ruin the “O” rings.  
S Do not use contaminated air supply.  
S Donot use light weight oilin air supply, it willwash theKey-Lube  
grease out of the air motor section.  
DIMENSIONAL DATA  
Dimensions shown are for reference only, they are shown in inches and millimeters (mm).  
Material Outlet  
16-1/16” (407.4 mm)  
8” (203.2 mm)  
13-5/8”  
(346.1 mm)  
12-9/16”  
(318.7 mm)  
7-17/32”  
(190.8 mm)  
2”  
(50.4 mm)  
6-17/32” (166.1 mm)  
8-3/16” (207.8 mm)  
13/32” Slot (9.9 mm)  
11-5/8” (295.3 mm)  
Air Inlet 3/8 - 18 N.P.T.F. - 1  
Material Inlet  
Material Inlet  
Material Outlet  
PH10A-ASS-XXT  
1 - 11-1/2 N.P.T.F. - 1  
1 - 11-1/2 N.P.T.F. - 1  
PH10A-BSS-XXT Rp 1 (1 - 11 BSP parallel) Rp 1 (1 - 11 BSP parallel)  
Figure 5  
PN 97999-801  
Page 8 of 8  
PH10A-XXX-XXX (en)  
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