AD40A-X-X
OPERATOR’S MANUAL
RELEASED: 4-22-05
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
REVISED:
12-2-10
(REV. 05)
1-1/2” 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 material options.
637436 for air section repair (see page 6).
637426-XX for fluid section repair (see page 4).
PUMP DATA
Models . . . . . . . . . . see “Model Description Chart” for “-XXX”
Pump Type . . . . . . . Metallic Air Operated Double Diaphragm
Material . . . . . . . . . . see “Model Description Chart”
Weight . . . AD40A-XAX-XXX . . . . . . . 50.9 lbs (23.1 kg)
AD40A-XCX-XXX . . . . . . 78.9 lbs (35.8 kg)
AD40A-XSX-XXX . . . . . . . 83.9 lbs (38.0 kg)
Maximum Air Inlet Pressure . . . . . . . . . 120 p.s.i. (8.3 bar)
Maximum Material Inlet Pressure . . . . . 10 p.s.i. (0.69 bar)
AD40A-XXX-XXX
Maximum Outlet Pressure . . . . . . . . . . 120 p.s.i. (8.3 bar)
Maximum Flow Rate (flooded inlet) . . . 90 g.p.m. (340.7 l.p.m.)
Displacement / Cycle @ 100 p.s.i.g. . . . 0.64 gal. (2.42 lit.)
Maximum Particle Size . . . . . . . . . . . . 1/4” dia. (6.4 mm)
Maximum Temperature Limits (diaphragm / ball / seat material)
E.P.R. / EPDM . . . . . . -60_ to 280_ F (-51_ to 138_ C)
HytrelR . . . . . . . . . . . -20_ to 150_ F (-29_ to 66_ C)
Polypropylene . . . . . . . 35_ to 175_ F (2_ to 79_ C)
1-1/2’’ DIAPHRAGM PUMP
MODEL DESCRIPTION CHART
AD40 A - X X X - X X X
CENTER SECTION MATERIAL
A - Aluminum
SantopreneR . . . . . . . -40_ to 225_ F (-40_ to 107_ C)
PTFE . . . . . . . . . . . . . 40_ to 225_ F (4_ to 107_ C)
VitonR . . . . . . . . . . . . -40_ to 350_ F (-40_ to 177_ C)
Dimensional Data . . . . . . . . . . . . . . . . see page 8
Noise Level @ 70 p.s.i., 60 c.p.m. . . . 77.7 db(A)*
THREAD
A - 1-1/2” N.P.T.F. - 1
B - Rp 1-1/2 - 11 BS
FLUID CAPS & MANIFOLD MATERIAL
A - Aluminum
C - Cast iron
S - Stainless Steel
Tested with 93139 muffler assembly installed.
The pump sound pressure levels published here have been updated to an Equivalent Continuous
Sound Level (L ) to meet the intent of ANSI S1.13-1971, CAGI-PNEUROP S5.1 using four mi-
Aeq
HARDWARE MATERIAL
P - Carbon Steel
S - Stainless Steel
crophone 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.
SEAT MATERIAL
F - Aluminum
P - Polypropylene
S - 316 Stainless Steel
BALL MATERIAL
A - Santoprene
C - Hytrel
T - PTFE
DIAPHRAGM MATERIAL
A - Santoprene
C - Hytrel
T - PTFE
FLUID SECTION SERVICE KIT SELECTION
AD40A - XXX - X X X
637426 - X X
EXAMPLE: MODEL # AD40A-ASS-SAA
FLUID SECTION SERVICE KIT # 637426-AA
Ball
Diaphragm
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET – BRYAN, OHIO 43506
© 2010
(800) 495-0276 FAX(800) 892-6276
CCN 15242621
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GENERAL DESCRIPTION
MAINTENANCE
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 / fluid sections.
Air operated double diaphragm pumps utilize a pressure differential in
theairchamberstoalternatelycreatesuctionandpositivefluidpressure
in the fluid chambers, ball checks insure a positive flow of fluid.
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 pres-
sure and will stop cycling once maximum line pressure is reached (dis-
pensing device closed) and will resume pumping as needed.
Refertothepartviewsanddescriptionsasprovidedonpage4through7
for parts identification and Service Kit information.
S Certain ARO “Smart Parts” are indicated which should be available
for fast repair and reduction of down time.
S Service kits are divided to service two separate diaphragm pump
functions: 1. AIR SECTION, 2. FLUID SECTION. The FLUID SEC-
TION is divided further to match typical part MATERIAL OPTIONS.
S Provide a clean work surface to protect sensitive internal moving
partsfromcontaminationfromdirtandforeignmatter duringservice
disassembly and reassembly.
S Keep good records of service activity and include pump in preven-
tive maintenance program.
S Before disassembling, empty captured material in the outlet man-
ifold by turning the pump upside down to drain material from the
pump.
AIR AND LUBE REQUIREMENTS
WARNING EXCESSIVE AIR PRESSURE. Can cause pump
damage, personal injury or property damage.
S Afiltercapableoffilteringoutparticleslargerthan50micronsshould
beusedontheairsupply. Thereisnolubricationrequiredotherthan
the “O” ring lubricant which is applied during assembly or repair.
S If lubricated air is present, make sure that it is compatible with the
Nitrile “O” rings in the air motor section of the pump.
FLUID SECTION DISASSEMBLY
1. Remove top manifold(s).
2. Remove (22) balls, (19) “O” rings, (21) seats.
3. Remove (15) fluid caps.
NOTE:OnlyPTFEdiaphragmmodelsuseaprimarydiaphragm(7)anda
backup diaphragm (8). Refer to the auxiliary view in the Fluid Section il-
lustration.
4. Remove the (6) nut, (7) or (7 / 8) diaphragms and (5) washers.
5. Remove (3) “O” rings.
NOTE: Do not scratch or mar the surface of (1) diaphragm rod.
OPERATING INSTRUCTIONS
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.
FLUID SECTION REASSEMBLY
S Theoutletmaterialvolumeisgovernednotonlybytheairsupplybut
alsobythematerialsupplyavailableattheinlet.Thematerialsupply
tubing should not be too small or restrictive. Be sure not to use hose
which might collapse.
S 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.
S Secure the diaphragm pump legs to a suitable surface to insure
against damage by vibration.
S Reassemble in reverse order.
S Clean and inspect all parts. Replace worn or damaged parts with
new parts as required.
S Lubricate(1)diaphragmrodand(2)“O”ringwithKey-LubeR grease.
S UseAROpn/98931-Tbullet(installationtool)toaidininstallationof
(2) “O” ring on (1) diaphragm rod.
S Be certain (7) or (7 / 8) diaphragm(s) align properly with (15) fluid
caps before making final torque adjustments on bolt and nuts to
avoid twisting the diaphragm.
S FormodelswithPTFEdiaphragms:Item(8)Santoprenediaphragm
is installed with the side marked “AIR SIDE” towards the pump cen-
ter body. Install the PTFE diaphragm with the side marked “FLUID
SIDE” towards the fluid cap.
S Re-check torque settings after pump has been re-started and run a
while.
S VitonR and HytrelR are trademarks of the DuPont Company, S SantopreneR is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. S Key-LubeR is a registered trademark of Key Industries
AD40A-X-X
Page 3 of 8
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PARTS LIST / AD40A-X-X FLUID SECTION
FLUID SECTION SERVICE KITS
L KITS INCLUDE: BALLS (See BALL Option, refer to -XX in chart below), DIAPHRAGMS (See DIAPHRAGM Option, refer to -XX in chart below),
plus “O” Ring items: 2, 3, 19 and 93706-1 Key-Lube grease.
SEAT OPTIONS
AD40A-XXX-XXX
“21”
BALL OPTIONS
AD40A-XXX-XXX
L “22” (1-3/4” dia.)
MATERIAL CODE
[A] = Aluminum
[H] = Hytrel
[B] = Nitrile
[P] = Polypropylene
[SP] = Santoprene
[SS] = Stainless Steel
[T] = PTFE
[C] = Carbon Steel
[CI] = Cast Iron
[Co] = Copper
[E] = E.P.R.
-XXX Seat
Qty [Mtl]
-XXX Ball
Qty [Mtl]
[V] = Viton
-FXX 92760
-PXX 92924
-SXX 92776
(4)
(4)
[A]
[P]
-XAX 92757-A
-XCX 92757-C
-XTX 92757-4
(4) [SP]
(4)
(4)
[H]
[T]
(4) [SS]
DIAPHRAGM OPTIONS AD40A-XXX-XXX
L Service Kit
L “7”
L “8”
L “3”
L “19”
“O” Ring
“O” Ring
Qty [Mtl] (1/8” x 2-3/4” o.d.)
-XX = (Ball)
-XX = (Diaphragm)
-XXX
Diaphragm Qty [Mtl] Diaphragm Qty [Mtl] (1/16” x 3/4” o.d.)
Qty [Mtl]
-XXA 637426-XA
-XXC 637426-XC
-XXT 637426-XT
94615-A
94615-9
94617
(2) [SP] - - - - -
- - -
- - -
- - - Y328-16
- - - Y328-16
(4)
(4)
(4)
[T] 92761
[T] Y327-230
[T] Y220-230
(4)
(4)
(4)
[E]
[V]
[T]
(2)
(2)
[H] - - - - -
[T] 94616
(2) [SP] Y328-16
MANIFOLD / FLUID CAP MATERIAL OPTIONS AD40A-XXX-XXX
ALUMINUM
CAST IRON
STAINLESS STEEL
AD40A-AAX- AD40A-BAX- AD40A-ACX- AD40A-BCX- AD40A-ASX- AD40A-BSX-
N.P.T.
BSP
N.P.T.
BSP
N.P.T.
BSP
Item Description (size)
V 6 Plate (fluid side)
15 Fluid Cap
Qty Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl]
(2) 92752
(2) 92750
(2) 92749
[C] 92752
[A] 92750
[A] 92749-1
[C] 92752
[A] 92778
[A] 92777
[C] 92752
[CI] 92778
[C] 92775
[CI] 92773
[SS] 92775
[SS] 92773
[SS]
[SS]
16 Manifold
[CI] 92777-1 [CI] 92774
[SS] 92774-1 [SS]
HARDWARE OPTIONS AD40A-XXX-XXX
Carbon Steel
Stainless Steel
AD40A-XXP-XXX AD40A-XXS-XXX
Item Description (size)
26 Bolt (3/8” - 16 x 1-1/4”)
27 Bolt (5/16” - 18 x 2-1/4”)
29 Nut (5/16” - 18)
Qty Part No.
(8) Y6-66-C
(4) Y6-510-C
(20) Y12-5-C
(2) 92759
[Mtl] Part No.
[C] Y6-66-T
[C] Y6-510-T
[C] Y12-5-S
[C] 92759-1
[C] Y6-59-T
[Mtl]
[SS]
[SS]
[SS]
[SS]
[SS]
32 Leg
59 Bolt (5/16” - 18 x 2”)
(16) 93608
COMMON PARTS
Item Description (size)
V 1 Rod
Qty Part No.
(1) 98720-1
(1) Y330-117
(2) 92752
[Mtl]
Item Description (size)
Qty Part No.
(2) 93065
[Mtl]
[SS]
[SS]
[Co]
[C]
9
Washer (0.630” i.d.)
L 2 “O” Ring (3/32” x 1” o.d.) k
[B]
14 Screw (5/8” - 18 x 1-1/2”)
43 Ground Lug (see page 7)
(2) Y5-107-T
(1) 93004
5
Plate - (air side)
[C]
Service Note: Part No. 98931-T installation tool is available separately for use with items 1 and 2.
V “Smart Parts” keep these items on hand in addition to the Service Kits for fast repair and reduction of down time.
Page 4 of 8
AD40A-X-X
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PARTS LIST / AD40A-X-X FLUID SECTION
FOR THE
AIR MOTOR SECTION
SEE PAGES 6 & 7
COLOR CODE
. TORQUE REQUIREMENTS ,
DIAPHRAGM
COLOR
BALL
COLOR
Cream
Cream
N/A
NOTE: DO NOT OVERTIGHTEN FASTENERS
MATERIAL
Hytrel
Santoprene
Santoprene
(Backup)
PTFE
Cream
(14) Diaphragm bolt, 65 - 70 ft lbs (88.1 - 94.9 Nm), apply Loctite 271 to threads.
(26) Bolts and (29) nuts, 120 - 140 in. lbs (13.6 - 15.8 Nm).
Cream
*
Green
White
White
LUBRICATION / SEALANTS
k Apply Key-Lube to all “O” rings, “U” Cups & mating parts.
Apply anti-seize compound to threads and bolt and nut flange heads which
contact pump case when using stainless steel fasteners.
See item 8 in inset below.
*
16
26 ,
d NOTE: Radius edge of parts (5 and 6) is against diaphragm.
29 ,
1
2 k
3 k
5 d
7
k 3
14 ,
22
19 k
21
15
59
32
27
Tab
6 d
9
22
16
21
26 ,
19 k
Santoprene 8
(Green when used as backer)
7 PTFE
Countersink
Figure 1
1
3
Fluid
Side
8
5
Air
Side
Air
Side
10
9
Fluid
Side
6
7
4
2
Tab
Torque Sequence
View for AD40A-XXX-XXT (PTFE diaphragm) configuration only.
Cross Section View of Diaphragms
AD40A-X-X
Page 5 of 8
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PARTS LIST / AD40A-X-X AIR MOTOR SECTION
n Indicates parts included in 637436 Air Section Service Kit.
SERVICEKITNOTE:ServiceKit637436isageneralrepairkitforall1”andlargerAROdiaphragmpumpairmotors.Itcontainsextra“O”
rings and extra parts that may not be needed to service this model.
Item Description (size)
101 Motor Body
Qty Part No.
(1) 94744
[Mtl]
[A]
Item Description (size)
n117 Gasket
Qty Part No.
(1) 92004
[Mtl]
[B/Ny]
[C]
n102 “O” Ring (1/16” x 1-1/4” o.d.)
V 103 Sleeve
(2) Y325-24
(1) 94528
[B]
118 Pilot Rod
(1) 93309-2
(4) 93075
[D]
n119 “O” Ring (1/8” x 3/4” o.d.)
120 Spacer
[U]
n104 Retaining Ring, TruArc (1-5/32” i.d.)
(2) Y145-26
[C]
(3) 115959
(2) 98723-2
(2) 94820
[Z]
105 Screw/Wshr (1/4”-20 x 5/8”) (AD40A-XXP-) (8) 93860
[C]
121 Sleeve Bushing
[Bz]
[U]
Cap Screw (1/4”-20 x 5/8”) (AD40A-XXS-)
106 Lockwasher (1/4”) (AD40A-XXS-)
107 Plate
(8) Y6-42-T
(8) Y14-416-T
(2) 93707-1
(1) 92878
[SS]
[SS]
[SS]
[B/Ny]
[D]
n122 “O” Ring (3/32” x 9/16” o.d.)
n123 Screw (#8 - 32 x 3/8”)
126 Pipe Plug (1/2 - 14 P.T.F. x 17/32”)
127 90_ Street Elbow (3/4 - 14 N.P.T.)
128 Pipe Plug (1/8 - 27 P.T.F. x 1/4”)
133 Lockwasher (1/4”)
(4) Y154-41
(1) Y227-5-L
(1) Y43-5-C
(1) Y227-2-L
(1) Y14-416-T
(2) 94987
[C]
[C]
n108 Gasket (with notch)
V 109 Piston
[C]
(1) 92011
[C]
n110 “U” Cup (3/16” x 1-3/8” o.d.)
V 111 Spool
(1) Y186-51
(1) 92005
[B]
[SS]
[SS]
[SS]
[P]
[A]
197 Button Head Screw (1/4” - 20 x 1/4”)
198 Button Head Screw (1/4” - 20 x 3/8”)
201 Muffler
V 112 Washer (1.557” o.d.)
n113 “O” Ring (small) (1/8” x 1-1/4” o.d.)
n114 “O” Ring (large) (3/32” x 1-9/16” o.d.)
V 115 Spacer
(5) 92877
[Z]
(1) 94987-1
(1) 93139
(5) Y325-214
(6) Y325-126
(4) 92876
[B]
[B]
[Z]
n
Key-Lube “O” Ring Lubricant
10 Pak of Key-Lube
(1) 93706-1
637175
V 116 Spacer
(1) 92006
[Z]
n Parts Y145-25 (0.925” i.d.) (qty 2) retaining rings and Y325-20 “O” rings
AIR MOTOR SECTION SERVICE
(qty 2) are included in the service kit for the repair of smaller pumps.
MATERIAL CODE
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.
GENERAL REASSEMBLY NOTES:
[A] = Aluminum
[B] = Nitrile
[D] = Acetal
[U] = Polyurethane
[SS] = Stainless Steel
[Z] = Zinc
[Ny] = Nylon
[P] = Polypropylene
S Air Motor Section Service is continued from Fluid Section repair.
S Inspect and replace old parts with new parts as necessary. Look for
deep scratches on metallic surfaces, and nicks or cuts in “O” rings.
S Take precautions to prevent cutting “O” rings upon installation.
S Lubricate “O” rings with Key-Lube grease.
S Do not over-tighten fasteners, refer to torque specification block on
view.
S Re-torque fasteners following restart.
[Bz] = Bronze
[C] = Carbon Steel
MAJOR VALVE DISASSEMBLY
1. Remove (107) plate (or leg depending on model), (108 and 117)
gaskets.
2. Onthesideoppositetheairinlet, pushontheinnerdiameterof(111)
spool.Thiswillforcethe(109)pistonout.Continuepushingthe(111)
spool and remove. Check for scratches and gouges.
3. Reach into the air section (exhaust side) and remove (116) spacer,
(115) spacers, (113) “O” rings, (114) “O” rings, (112) washers, etc.
Check for damaged “O” rings.
PILOT VALVE DISASSEMBLY
1. Remove (104) retaining ring.
2. Remove (123) screws and (122) “O” rings.
3. Remove (118) piston rod, (121) sleeve bushing, (119) “O” rings and
(120) spacers from the (101) motor body.
MAJOR VALVE REASSEMBLY
4. Remove (103) sleeve and (102) “O” rings.
1. Replace (112) washer, (114) “O” ring and (113) “O” ring onto (115)
spacer and insert etc.
PILOT VALVE REASSEMBLY
NOTE: Be careful to orient spacer legs away from blocking in-
ternal ports.
1. Replace two (102) “O” rings if worn or damaged and reinstall (103)
sleeve.
2. Install one of the (121) sleeve bushings, (119) “O” rings, (120)
spacers and the remaining (121) bushing.
3. Carefully push (118) pilot rod into bushings etc. and retain on each
end with the two (122) “O” rings, retain with (123) screws.
4. Replace (104) retaining rings.
2. Lubricate and carefully insert (111) spool.
3. Install (117) gasket and (107).
4. Lubricate and install (110) packing cup and insert (109) piston into
(airinletside)cavity,the(110)packingcuplipsshouldpointoutward.
5. Install (108) gasket and replace (107).
V “Smart Parts” Keep these items on hand in addition to the Service Kits for fast repair and reduction of down time.
Page 6 of 8
AD40A-X-X
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PARTS LIST / AD40A-X-X AIR MOTOR SECTION
IMPORTANT
117
BE CERTAIN TO ORIENT (115) SPACER LEGS
AWAY FROM BLOCKING INTERNAL PORTS
WHEN REASSEMBLING AIR SECTION.
105 ,
111
116
106
115
k 114
k 113
112
107
MAJOR VALVE
See cross section detail figure 3.
Figure 2
101
z 197
43
104
z 123
197 z
121
109
108
102 k
103 k
106
104
126 Z
107
PILOT VALVE
. 105
119 k
121
123 z 118 k
k 110
z 198
133
128 Z
120
127
201
122 k
MAJOR VALVE CROSS SECTION DETAIL
114 k
109 110 k
113 k
112
115
111
116
. TORQUE REQUIREMENTS ,
NOTE: DO NOT OVERTIGHTEN FASTENERS
(105) 40 - 50 in. lbs (4.5 - 5.6 Nm),
apply Loctite Nickel Antiseize to threads.
LUBRICATION / SEALANTS
Apply Key-Lube to all “O” rings, “U” Cups & mating parts.
k
z Apply Loctite 271 to threads.
Z Apply pipe sealant to threads.
Figure 3
AD40A-X-X
Page 7 of 8
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TROUBLE SHOOTING
Product discharged from exhaust outlet.
S Check for diaphragm rupture.
S Check tightness of diaphragm nut.
Low output volume, erratic flow, or no flow.
S Check air supply.
S Check for plugged outlet hose.
S Check for kinked (restrictive) outlet material hose.
S Check for kinked (restrictive) or collapsed inlet material hose.
S 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 a non-col-
lapsing type, capable of pulling a high vacuum.
S Check all joints on the inlet manifolds and suction connections.
These must be air tight.
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 diaphragm nut.
S Inspectthepumpforsolidobjectsloggedinthediaphragmchamber
or the seat area.
DIMENSIONAL DATA
(Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
13-1/8”
11-1/2”
(333 mm)
(292 mm)
Material Outlet
1-1/2 - 11-1/2 N.P.T.F.-1 (AD40A-AXX-XXX)
1-1/2 - 11 B.S.P. (AD40A-BXX-XXX)
Air Inlet 1/2 - 14 N.P.T.
18-3/8”
(467 mm)
19-5/8”
(498 mm)
7-5/8”
(194 mm)
2-3/4”
Air Exhaust Thread
3/4 - 14 N.P.T.
(70 mm)
10- 3/4” (273 mm)
12” (305 mm)
1/2” Slot
(14 mm)
9” (229 mm)
Material Inlet
1-1/2 - 11-1/2 N.P.T.F.-1 (AD40A-AXX-XXX)
1-1/2 - 11 B.S.P. (AD40A-BXX-XXX)
Figure 4
PN 97999-1153
AD40A-X-X
Page 8 of 8
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