Ingersoll Rand Marine Sanitation System PD20R X User Manual

PD20R-X  
OPERATOR’S MANUAL  
RELEASED: 9-12-03  
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE  
REVISED:  
11-11-10  
(REV. 07)  
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.  
637309-XXforfluidsectionrepair(seepage4).NOTE:Thiskitalsocon-  
tains several air motor seals which will need to be replaced.  
637369 for air section repair (see page 6).  
637374 major air valve assembly (see page 7).  
PUMP DATA  
Models . . . . . . . . . . . . . see Model Description Chart for “-XXX”.  
Pump Type . . . . . . . . . . MetallicAirOperatedDoubleDiaphragm  
Material . . . . . . . . . . . . . see Model Description Chart.  
Weight . . PD20X-XCX-XXX . . . . . . 165 lbs (74.8 kgs)  
PD20X-AHX-XXX . . . . . . 154 lbs (69.9 kgs)  
Figure 1  
PD20X-ASX-XXX . . . . . . 154 lbs (69.9 kgs)  
PD20X-BHX-XXX . . . . . . 154 lbs (69.9 kgs)  
MODEL DESCRIPTION CHART  
PD20X-BSX-XXX . . . . . . 154 lbs (69.9 kgs)  
PD20X-FHX-XXX . . . . . . 146 lbs (66.2 kgs)  
PD20 X - X X X - X X X  
PD20X-FSX-XXX . . . . . . 146 lbs (66.2 kgs)  
Maximum Air Inlet Pressure . . . . . . . 120 p.s.i.g. (8.3 bar)  
Maximum Material Inlet Pressure . . . 10 p.s.i.g. (0.69 bar)  
Maximum Outlet Pressure . . . . . . . . 120 p.s.i.g. (8.3 bar)  
Maximum Flow Rate (flooded inlet) . . 170 g.p.m. (644 l.p.m.)  
Displacement / Cycle @ 100 p.s.i.g. . 1.4 gal. (5.3 lit.)  
Maximum Particle Size . . . . . . . . . . 1/4” dia. (6.4 mm)  
Maximum Temperature Limits (diaphragm / ball / seal material)  
E.P.R. / EPDM . . . . . . . . . . . -60_to280_F (-51_to 138_C)  
HytrelR . . . . . . . . . . . . . . . . -20_ to 150_ F (-29_ to 66_ C)  
Nitrile . . . . . . . . . . . . . . . . . 10_ to 180_ F (-12_ to 82_ C)  
Polypropylene . . . . . . . . . . . 35_ to 175_ F (2_ to 79_ C)  
PVDF (KynarR) . . . . . . . . . . 10_ to 200_ F (-12_ to 93_ C)  
SantopreneR . . . . . . . . . . . . -40_to225_F (-40_to 107_C)  
PTFE . . . . . . . . . . . . . . . . . 40_ to 225_ F (4_ to 107_ C)  
VitonR . . . . . . . . . . . . . . . . . -40_to350_F (-40_to 177_C)  
Dimensional Data . . . . . . . . . . . . . . see page 8  
AIR MOTOR / AIR CAP MATERIAL  
R - Polypropylene / Stainless Steel  
Y - Polypropylene / Cast Iron  
THREAD  
A
B
F
- 2 - 11-1/2 N.P.T.F. - 1  
- Rp 2 (2 - 11 BSP parallel)  
- 2” A.N.S.I. / DIN Flange  
FLUID CAPS & MANIFOLD MATERIAL  
C
H
S
- Cast Iron  
- Hastelloy - C  
- Stainless Steel  
HARDWARE MATERIAL  
P
S
- Plated Steel  
- Stainless Steel  
SEAT MATERIAL  
A
C
E
F
- Santoprene  
- Hytrel  
H
K
L
- Hard 440 Stainless Steel  
- PVDF (Kynar)  
- Hastelloy - C  
- Carbon Steel  
- Aluminum  
- Nitrile  
Mounting Dimension . . . . . 9-1/16” x 10-1/16” (230 mm x 256 mm)  
Noise Level @ 70 p.s.i., 60 c.p.m.{ . . 85.0 db(A)|  
S
- 316 Stainless Steel  
G
BALL MATERIAL  
 Tested with 67263 muffler assembly installed.  
A
C
G
- Santoprene  
- Hytrel  
- Nitrile  
S
T
V
- 316 Stainless Steel  
- PTFE  
- Viton  
 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-PNEU-  
Aeq  
ROP S5.1 using four microphone locations.  
DIAPHRAGM MATERIAL  
NOTICE: All possible options are shown in the chart, however, certain combina-  
tions may not be recommended, consult a representative or the factory if you have  
questions concerning availability.  
A
C
G
- Santoprene  
- Hytrel  
- Nitrile  
M - Medical Grade Santoprene  
T
V
- PTFE / Santoprene  
- Viton  
FLUID SECTION SERVICE KIT SELECTION  
PD20X - XXX - X X X  
637309 - X X  
EXAMPLE: MODEL # PD20Y-ACP-SAA  
FLUID SECTION SERVICE KIT # 637309-AA  
Ball  
Diaphragm  
INGERSOLL RAND COMPANY  
209 NORTH MAIN STREET BRYAN, OHIO 43506  
(800) 276-4658 D FAX (800) 266-7016  
E2010  
CCN 15199078  
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GENERAL DESCRIPTION  
PARTS AND SERVICE KITS  
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, valve 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.  
MAINTENANCE  
S Provide a clean work surface to protect sensitive internal moving  
partsfrom contaminationfrom dirtandforeignmatter 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 (61) outlet manifold, (60) inlet manifold.  
2. Remove (22) balls, (19) “O” rings (if applicable) and (21) seats.  
3. Remove (15) fluid caps.  
OPERATING INSTRUCTIONS  
NOTE: Only PTFE diaphragm models use a primary diaphragm (7) and  
a backup diaphragm (8). Refer to the auxiliary view in the Fluid Section  
illustration.  
S Always flush the pump with a solvent compatible with the material  
being pumped ifthe materialbeing pumpedissubjectto “settingup”  
when not in use for a period of time.  
4. Removethe(6)diaphragmwasher,(7)or(7/8)diaphragms,and(5)  
backup washer.  
S Disconnecttheairsupplyfromthepumpifitistobeinactiveforafew  
hours.  
NOTE: Do not scratch or mar the surface of (1) diaphragm rod.  
S Theoutletmaterialvolumeisgovernednotonlybytheairsupplybut  
alsobythematerialsupplyavailableattheinlet.Thematerialsupply  
tubing should not be too small or restrictive. Be sure not to use hose  
which might collapse.  
FLUID SECTION REASSEMBLY  
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. Refer to the torque requirements on  
page 5.  
S Clean and inspect all parts. Replace worn or damaged parts with  
new parts as required.  
S Lubricate (1) diaphragm rod and (144) “U” cup with LubriplateR  
FML-2 grease (94276 grease packet is included in service kit).  
S FormodelswithPTFEdiaphragms:Item(8)Santoprenediaphragm  
is installed with the side marked “AIR SIDE” towards the pump cen-  
ter body. Install the PTFE diaphragm (7) with the side marked  
“FLUID SIDE” towards the (15) fluid cap.  
S Re-check torque settings after pump has been re-started and run a  
while.  
VitonR and HytrelR are trademarks of the DuPont Company,  
S
KynarR is a registered trademark of Penwalt Corp.  
LubriplateR is a registered trademark of Lubriplate Division (Fiske Brothers)  
SantopreneR is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P.,  
S
PD20R-X  
Page 3 of 8  
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PARTS LIST / PD20X-X-X FLUID SECTION  
FLUID SECTION SERVICE KITS (637309-XX)  
L KITS INCLUDE: BALLS (see Ball Option, refer to -XX in chart below), DIAPHRAGMS (see Diaphragm Option, refer to -XX in chart below), and items  
19, 70, 144, 175, (listed below) plus 174 and 94276 Lubriplate FML-2 grease (page 6).  
SEAT OPTIONS PD20X-XXX-XXX  
BALL OPTIONS PD20X-XXX-XXX  
“21”  
L “22” (2-1/2” dia.)  
-XXX Seat  
Qty [Mtl]  
(4) [SP]  
-XXX Seat  
Qty [Mtl]  
(4) [SH]  
-XXX Ball  
Qty [Mtl]  
(4) [SP]  
-XXX Ball  
Qty [Mtl]  
(4) [SS]  
-AXX 94328-A  
-CXX 94328-C  
-EXX 95677  
-FXX 95673  
-GXX 94328-G  
-HXX 94354  
-KXX 94477-K  
-LXX 95639  
-SXX 94353  
-XAX 93358-A  
-XCX 93358-C  
-XGX 93358-2  
-XSX 94805  
-XTX 93358-4  
-XVX 93358-3  
(4)  
(4)  
(4)  
(4)  
[H]  
[C]  
[A]  
[B]  
(4)  
[K]  
(4)  
(4)  
[H]  
[B]  
(4)  
(4)  
[T]  
[V]  
(4) [Ha]  
(4) [SS]  
DIAPHRAGM OPTIONS PD20X-XXX-XXX  
MATERIAL CODE  
[A] = Aluminum  
[B] = Nitrile  
[C] = Carbon Steel  
[Co] = Copper  
[CI] = Cast Iron  
[E] = E.P.R.  
[H] = Hytrel  
[Ha] = Hastelloy - C  
[K] = PVDF (Kynar)  
[MSP]=MedicalGradeSantoprene  
[SH] = Hard Stainless Steel  
[SP] = Santoprene  
[SS] = Stainless Steel  
[T] = PTFE  
[V] = Viton  
L Service Kit  
-XX = (Ball)  
L “7”  
L “8”  
L “19”  
“O” Ring  
-XXX -XX = (Diaphragm) Diaphragm Qty [Mtl] Diaphragm Qty [Mtl] (1/8” x 3-5/8” o.d.) Qty [Mtl]  
-XXA 637309-XA  
-XXC 637309-XC  
-XXG 637309-XG  
-XXM 637309-XM  
-XXT 637309-XT  
-XXV 637309-XV  
94329-A  
94329-C  
94329-G  
94329-M  
94355-T  
95344  
(2)  
(2)  
(2)  
[SP] - - - - -  
- - -  
- - -  
- - -  
- - -  
- - - 94356  
(4)  
(4)  
(4)  
(4)  
(4)  
(4)  
[E]  
[V]  
[B]  
[T]  
[T]  
[V]  
[H]  
[B]  
- - - - -  
- - - - -  
- - - Y327-237  
- - - Y325-237  
- - - Y328-237  
(2) [MSP] - - - - -  
(2)  
(2)  
[T]  
[V]  
94330-A  
- - - - -  
(2) [SP] Y328-237  
- - - - - - Y327-237  
NOTE: Seat options -AXX, -CXX and -GXX do not require item 19 “O” ring.  
MANIFOLD THREAD / FLUID CAP MATERIAL OPTIONS PD20X-XXX-XXX  
PD20X-XCX-  
PD20X-XHX-  
PD20X-FHX-  
PD20X-XSX-  
PD20X-FSX-  
Item Description (size)  
Qty Part No.  
(2) 94357-2  
(2) 93065  
(2) Y5-111-T  
(2) 94346  
(1) 94347-(l)  
(1) 94348-(l)  
(2) Y17-28-C  
(2) 94439-1  
[Mtl] Part No.  
[Mtl] Part No.  
[Mtl] Part No.  
[Ha] 94357-2  
[Ha] 93065  
[Ha] Y5-111-T  
[Ha] 95570  
[Ha] 95510-(l)  
[Ha] 95511-(l)  
- - - - - - - -  
[Mtl] Part No.  
[Mtl]  
[SS]  
[SS]  
[SS]  
[SS]  
[SS]  
[SS]  
- - -  
6
9
Diaphragm Washer  
Washer  
[SS] 94357-3  
[SS] 95683  
[SS] 95682  
[CI] 95679  
[CI] 95680-(l)  
[CI] 95681-(l)  
[C] - - - - -  
[Ha] 94357-3  
[Ha] 95683  
[Ha] 95682  
[Ha] 95679  
[Ha] 96341 u  
[Ha] 96342 u  
- - - - - - - -  
[SS] 94357-2  
[SS] 93065  
[SS] Y5-111-T  
[SS] 95570  
[SS] 95512 u  
[SS] 95513 u  
- - - - - - - -  
14 Screw (5/8” - 18 x 2-1/2”)  
15 Fluid Cap  
60 Inlet Manifold  
61 Outlet Manifold  
63 Pipe Plug (2 - 11-1/2 N.P.T.)  
(R-2, 2 - 11 BSP)  
[C] - - - - -  
- - - - - - - -  
- - - - - - - -  
- - - - - - - -  
- - -  
l For N.P.T.F. thread models (PD20X-AXX-XXX), use “-1”  
l For BSP thread models (PD20X-BXX-XXX), use “-2”  
u
Flange models  
EXTERNAL HARDWARE OPTION PD20X-XXX-XXX  
PD20X-XXP-XXX PD20X-XXS-XXX  
Item Description (size)  
26 Screw (M10 x 1.5 - 6g x 35 mm)  
27 Screw (M10 x 1.5 - 6g x 45 mm)  
29 Nut (M10 x 1.5 - 6g)  
Qty Part No.  
(8) 94409-1  
(16) 94990-1  
(16) 94992-1  
[Mtl] Part No.  
[C] 94409-2  
[C] 94990  
[C] 94992  
[Mtl]  
[SS]  
[SS]  
[SS]  
COMMON PARTS  
Item  
Description (size)  
Rod  
Qty Part No.  
(1) 94358  
[Mtl]  
[C]  
Item  
Description (size)  
Qty Part No.  
(2) Y17-51-S  
(4) 94531  
(2) Y186-51  
(2) Y325-117  
(4) 94098  
[Mtl]  
[SS]  
[C]  
[B]  
[B]  
1
5
126 Pipe Plug (1/4 - 18 N.P.T. x 0.41”)  
131 Screw (M10 x 1.5 - 6g x 120 mm)  
Ln144 “U” Cup (3/16” x 1-3/8” o.d.)  
Ln175 “O” Ring (3/32” x 1” o.d.)  
n 180 Washer (0.406” i.d. x 0.031” thick)  
181 Roll Pin (0.156” o.d. x 3/4” long)  
Backup Washer  
(2) 94357-2  
(1) 94349-1  
(1) 94345-1  
(1) 94349-2  
(1) 94345-2  
(2) 94100  
[SS]  
[SS]  
[CI]  
[SS]  
[CI]  
[B]  
68 Air Cap (models PD20R-XXX-XXX)  
(models PD20Y-XXX-XXX)  
69 Air Cap (models PD20R-XXX-XXX)  
(models PD20Y-XXX-XXX)  
[Co]  
[SS]  
(4) Y178-56-S  
L n 70 Gasket  
V “Smart Parts” - Keep these items on hand in addition to the Service Kits for fast repair and reduction of down time.  
n Air Motor Kit parts, see page 6.  
Page 4 of 8  
PD20R-X  
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PARTS LIST / PD20X-X-X FLUID SECTION  
COLOR CODE  
DIAPHRAGM  
COLOR  
3
2
1
4
BALL  
COLOR  
MATERIAL  
8
6
5
7
Hytrel  
Nitrile  
Cream  
Black  
Tan  
Cream  
Red (S)  
Tan  
61 (PD20X-FXX-XXX)  
Santoprene  
Santoprene  
(Backup)  
PTFE  
Green  
N / A  
White  
Yellow (-)  
(-) Dash  
White  
Yellow (S)  
(S) Dot  
Viton  
Torque Sequence  
61 (PD20X-AXX-XXX)  
(PD20X-BXX-XXX)  
FOR THE  
AIR MOTOR SECTION  
SEE PAGES 6 & 7  
26 ,G  
181  
175 k 144 k  
144 k 70 k 1 k  
5
7
9
22  
21  
19 z  
27 ,G  
68 126 s 70 k  
175 k  
15  
29 69  
180 131 ,x  
6
14 ,  
60 (PD20X-AXX-XXX)  
(PD20X-BXX-XXX)  
22  
63 s  
21  
26 ,G  
19 z  
60 (PD20X-FXX-XXX)  
. TORQUE REQUIREMENTS ,  
NOTE: DO NOT OVERTIGHTEN FASTENERS.  
ALL FASTENERS ARE METRIC.  
VIEW OF TWO PIECE PTFE DIAPHRAGM  
(14) Diaphragm screw, apply Loctite #271 to threads,  
65 - 70 ft lbs (88.1 - 94.9 Nm).  
(26 and 27) Fluid caps / manifold screws 30 - 40 ft lbs  
(40.7 - 54.2 Nm).  
(131) Screw 35 - 40 ft lbs (47.5 - 54.2 Nm).  
G Apply anti-seize compound to threads when using  
stainless steel fasteners and stainless steel wet ends.  
LUBRICATION / SEALANTS  
k Apply Lubriplate FML-2 grease to all “O” rings,  
“U” Cups & mating parts.  
x Apply Loctite 242 to threads at assembly.  
s Apply PTFE tape to threads at assembly.  
7 PTFE  
Santoprene 8  
z Not used with PD20X-XXX-AXX, -CXX & -GXX.  
Z Lubriplate FML-2 is a white food grade petroleum grease.  
Figure 2  
PD20R-X  
Page 5 of 8  
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PARTS LIST / PD20X-X-X AIR SECTION  
n Indicates parts included in 637369 Air Section Service Kit shown below and items (70), (144), (175) and (180) shown on page 4.  
AIR MOTOR PARTS  
Item  
Description (size)  
Qty Part No.  
(1) 95667  
(1) 94092  
(4) 95921  
(2) 95846  
(1) 95651  
(2) 94083  
(2) 94084  
(1) 94860  
(1) 94099  
(8) 95931  
(8) 95923  
(1) 95789  
(1) 95790  
(1) Y325-32  
(1) 95966  
(1) Y186-50  
(1) 95650  
(1) 95659  
(1) Y325-208  
(1) Y325-204  
(1) 94026  
(1) 67164  
[Mtl]  
Item  
Description (size)  
Qty Part No.  
(2) 94433  
(1) Y240-9  
(1) 94081  
(1) Y325-119  
(1) Y325-22  
(2) Y325-26  
(2) Y325-202  
(2) 94102  
(1) 95666  
(1) 95665  
(1) 94810  
(2) Y325-202  
(1) 95761  
(4) 95924  
(1) 94276  
637308  
[Mtl]  
[U]  
101 Center Body  
[P]  
168 “O” Ring (3/32” x 5/8” o.d.)  
169 “U” Cup (1/8” x 7/8” o.d.)  
170 Piston Sleeve  
103 Bushing  
[D]  
[B]  
105 Screw (M6 x 1 - 6g x 180 mm)  
107 End Plate  
[SS]  
[SS]  
[D]  
[Br]  
[B]  
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 (1/16” x 1-3/8” o.d.)  
Kn 174 “O” Ring (1/8” x 1/2” o.d.)  
n 176 Diaphragm (check valve)  
n 199 Track Gasket  
111 Spool  
[B]  
118 Actuator Pin (0.250” x 2.276” long)  
121 Sleeve  
[SS]  
[D]  
[B]  
[B]  
~ 127 90 St. Elbow (1-1/2 - 11-1/2 N.P.T.)  
n 132 Gasket  
[C / I]  
[B]  
[SP]  
[B]  
133 Washer (M6)  
[SS]  
[SS]  
[P]  
n 200 Gasket  
[B]  
134 Screw (M6 x 1 - 6g x 35 mm)  
135 Valve Block  
~ 201 Muffler  
n 232 “O” Ring (1/8” x 1/2” o.d.)  
233 Adapter Plate  
[B]  
[P]  
136 End Cap  
[P]  
n 137 “O” Ring (1/16” x 2” o.d.)  
n 138 “U” Cup (3/16” x 1.792” o.d.)  
n 139 “U” Cup (3/16” x 1-1/4” o.d.)  
140 Valve Insert  
[B]  
236 Nut (M6 x 1 - 6g)  
[SS]  
[B]  
L n Lubriplate FML-2 Grease  
Lubriplate Grease Packets (10)  
[B]  
[Ck]  
[Ck]  
[B]  
~
Items not shown  
141 Valve Plate  
n 146 “O” Ring (1/8” x 7/8” o.d.)  
n 147 “O” Ring (1/8” x 5/8” o.d.)  
n 166 Track Gasket  
n 167 Pilot Piston (includes 168 and 169)  
MATERIAL CODE  
[B]  
[B] = Nitrile  
[D] = Acetal  
[SP] = Santoprene  
[SS] = Stainless Steel  
[U] = Polyurethane  
[Br] = Brass  
[I] = Iron  
[B]  
[C] = Carbon Steel  
[Ck] = Ceramic  
[P] = Polypropylene  
[D]  
K
Fluid Section Service Kit parts, see page 4.  
AIR MOTOR SECTION SERVICE  
MAJOR VALVE DISASSEMBLY  
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.  
GENERAL REASSEMBLY NOTES:  
1. Remove (135) valve block and (233) adapter plate, exposing (132  
and 166) gaskets, (232) “O” ring and (176) checks.  
2. Remove (233) adapter plate, releasing (140) valve insert, (141)  
valveplate,(199and200)gasketsand(146,147and232)Orings.  
3. Remove (136) end cap and (137) “O” ring, releasing (111) spool.  
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 surfaces, and nicks or cuts in “O” rings.  
S Take precautions to prevent cutting “O” rings upon installation.  
S Lubricate “O” rings with Lubriplate FML-2 grease.  
S Do not over-tighten fasteners, refer to torque specification block on  
view.  
S Re-torque fasteners following restart.  
S SERVICE TOOLS -- To aid in the installation of (168) “O” rings onto  
the (167) pilot piston, use tool # 204130-T, available from ARO.  
MAJOR VALVE REASSEMBLY  
1. Install new (138 and 139) “U” cups on (111) spool -- LIPS MUST  
FACE EACH OTHER.  
2. Insert (111) spool into (135) valve block.  
3. Install (137) “O” ring on (136) end cap and assemble end cap to  
(135) valve block, securing with (107) end plates and (105) screws.  
4. Install(140)valveinsertand(141)valveplateinto(135)valveblock.  
NOTE: Assemble (140) valve insert with “dished” side toward (141)  
valve plate. Assemble (141) valve plate with 2 identification dots to-  
ward (199 and 200) gaskets.  
PILOT VALVE DISASSEMBLY  
1. A light tap on (118) should expose the opposite (121) sleeve, (167)  
pilot piston and other parts.  
2. Remove (170) sleeve, inspect inner bore of sleeve for damage.  
5. Assemble (146, 147 and 232) “O” rings, (199 and 200) gaskets and  
(233) adapter plate to (135) valve block.  
6. Assemble(132and166)gaskets,(176)checksand(232)Oringto  
(101) body.  
PILOT VALVE REASSEMBLY  
7. Assemble (135) valve block and components to (101) body, secur-  
ing with (134) screws.  
1. Clean and lubricate parts not being replaced from service kit.  
2. Install new (171 and 172) “O” rings, replace (170) sleeve.  
3. Installnew (168) “O” ringsand(169) seal -Note thelip direction. Lu-  
bricate and replace (167).  
4. Reassemble remaining parts, replace (173 and 174) “O” rings.  
Page 6 of 8  
PD20R-X  
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PARTS LIST / PD20X-X-X AIR SECTION  
118  
169 k 168 k  
172 k  
171 k  
PILOT VALVE  
PART GROUP  
121  
k 174  
170  
k 173  
167  
140  
141 k 199 k 146 k 147 k 132 k 166 k  
173 k  
121  
107  
. 105  
133  
118  
174 k  
135  
103  
101  
. 134  
200 k 232 k 233 232 k 176 k  
138 k  
Optional 94117 Muffler  
MAJOR  
VALVE  
111  
139 k  
137 k  
136  
107  
236  
. TORQUE REQUIREMENTS ,  
NOTE: DO NOT OVERTIGHTEN FASTENERS.  
ALL FASTENERS ARE METRIC.  
Torque (105) screw to 35 - 40 in. lbs (4.0 - 4.5 Nm).  
Torque (134) screw to 35 - 40 in. lbs (4.0 - 4.5 Nm).  
LUBRICATION / SEALANTS  
Apply Lubriplate FML-2 grease to “O” rings, “U” Cups  
& mating parts.  
k
A 637374 replacement Major Valve Service Assembly is available separately, which includes the following:  
105 (4), 107 (2), 111, 132, 135, 136, 137, 138, 139, 140, 141, 146, 147, 166, 176 (2), 199, 200, 232 (2), 233 and 236 (4)  
Figure 3  
PD20R-X  
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TROUBLE SHOOTING  
Product discharged from exhaust outlet.  
S Check for diaphragm rupture.  
S Check tightness of (14) diaphragm screw.  
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 inlet side fluid caps.  
S Check tightness of (14) diaphragm screw.  
Motor blows air or stalls.  
S Check (176) check valve for damage or wear.  
S Check for restrictions in valve / exhaust.  
S Inspectthepumpforsolidobjectsloggedinthediaphragmchamber  
or the seat area.  
DIMENSIONAL DATA  
(Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).  
P
(PD20X-AXX-XXX) 2 - 11-1/2 N.P.T.F. - 1  
(PD20X-BXX-XXX) Rp 2 (2 - 11 BSP parallel)  
E
L
F
L
Outlet  
B
N Bolt Circle  
Q
G
Air Inlet 3/4 - 14 N.P.T.  
B
R
D
D
Inlet  
Dotted lines show optional  
67263 muffler assembly.  
H
K
M
J
C
A
2” A.N.S.I. / DIN Flange  
(PD20X-FXX-XXX)  
Exhaust Port 1-1/2 - 11-1/2 N.P.S.M.  
DIMENSIONS  
A - see below  
E - 16-3/16” (411.2 mm)  
F - 12” (304.8 mm)  
G - 26-1/4” (666.8 mm)  
H - 9-1/16” (230.2 mm)  
J - 10-1/16” (255.6 mm)  
K - 9/16” (14.3 mm)  
L - see below  
N - 4.834” (122.8 mm)  
P - 21-5/8” (548 mm)  
Q - 27-7/8” (708.0 mm)  
R - 13-9/16” (344.5 mm)  
B - 24-3/4” (628.7 mm)  
C - 10-1/16” (255.6 mm)  
D - see below  
M - 5/8” (15.9 mm)  
“A”  
“D”  
“L”  
PD20X-XCX-XXX  
PD20X-AHX-XXX  
PD20X-ASX-XXX  
PD20X-BHX-XXX  
PD20X-BSX-XXX  
PD20X-FHX-XXX  
PD20X-FSX-XXX  
19-3/4” (501.4 mm)  
19-3/8” (492.1 mm)  
19-3/8” (492.1 mm)  
19-3/8” (492.1 mm)  
19-3/8” (492.1 mm)  
19-3/8” (492.1 mm)  
19-3/8” (492.1 mm)  
1-7/8” (47.6 mm)  
2-1/2” (63.5 mm)  
2-1/2” (63.5 mm)  
2-1/2” (63.5 mm)  
2-1/2” (63.5 mm)  
2-1/2” (63.5 mm)  
2-1/2” (63.5 mm)  
2” (50.8 mm)  
2-3/32” (53.0 mm)  
2-3/32” (53.0 mm)  
2-3/32” (53.0 mm)  
2-3/32” (53.0 mm)  
3-1/4” (82.6 mm)  
3-1/4” (82.6 mm)  
Figure 4  
PN 97999-1060  
PD20R-X  
Page 8 of 8  
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