OPERATOR’S MANUAL
PP20A-XXX-XXX
6-2-05
RELEASED:
REVISED:
(REV. 04)
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
6-21-10
2" DRY POWDER 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
PP20A-XXX-XXX Powder Pump
Refer to Model Description Chart to match the pump mate-
rial options.
7102 valve kit for repair of H254PS control valve.
104255 for repair of P29122-100 filter / regulator.
118597-002 spool kit for repair of A212PD 4-way alpha valve.
637309-XX for fluid section repair (see page 6). NOTE: This kit
also contains several air motor seals which will need to be
replaced.
637421 for air section repair (see page 8).
PUMP DATA
PP20A-XAX-XXX
PP20A-XSX-XXX
Models. . . . . . . . . . . . . see Model Description Chart for “-XXX”
Pump Type. . . . . . . . . Metallic, Dry Powder, Diaphragm Pump
Material. . . . . . . . . . . . see Model Description Chart
Specific Application for pumping powders up to 50 lb. / ft3
Weight . . . PP20A-XAX-XXX . . . . . . . . . . 99.4 lbs (45.1 kgs)
PP20A-XSX-XXX . . . . . . . . . . 157.8 lbs (71.6 kgs)
Maximum Air Inlet Pressure . . . . . . . . 50 p.s.i.g. (3.4 bar)
Maximum Fluidizing Pressure . . . . . . 100 p.s.i.g. (6.9 bar)
Maximum Particle Size . . . . . . . . . . . . . 1/4” dia. (6.4 mm)
Maximum Temperature Limits (diaphragm / ball / seal
materials)
PP20A-CXX-XXX
Figure 1
MODEL DESCRIPTION CHART
PP20A - X X X - X X X
Fluid Connection
A - 2 - 11-1/2 N.P.T.F. - 1
B - 2 - 11 BSP
C - 2-1/2”Tri-Clamp
Nitrile . . . . . . . . . . . . . . . . . . . . 10° to 180° F (-12° to 82° C)
Santoprene®. . . . . . . . . . . . . . -40° to 225° F (-40° to 107° C)
Dimensional Data. . . . . . . . . . . . . . . . . . . see page 12
Mounting Dimension . 9-1/16”x 10-1/16”(230 mm x 256 mm)
Fluid Cap & Manifold Material
A - Aluminum
S - Stainless Steel
Noise Level @ 70 p.s.i., 50 c.p.m. . . . . 83.0 db(A)
ꢀ
ꢁ
Hardware Material
P - Plated Steel
S - Stainless Steel
Tested with 94085 muffler assembly installed.
ꢀ
ꢁ
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.
Seat Material
A - Santoprene
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
M- Medical Grade Santoprene
Diaphragm Material
A - Santoprene
M- Medical Grade Santoprene
Fluid Section Service Kit Selection
PP20A - XXX - X X X
637309 - X X
EXAMPLE: Model #PP20A-AAS-AAA
Fluid Section Service Kit # 637309-AA
Ball
Diaphragm
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET – BRYAN, OHIO 43506
(800) 495-0276 FAX(800) 892-6276
© 2010
CCN 15235526
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small or restrictive, which will inhibit material flow. The
outlet material volume is governed not only by the air
supply, but also by the material volume available at the
inlet.
Air supply provided should be filtered to provide clean,
dry air. A filter capable of filtering out particles larger
than 40 microns should be used on the air supply. There
is no lubrication required other than the “O”ring lubricant
which is applied during assembly or repair.
If lubricated air is present, make sure that it is compatible
with the Nitrile “O” rings in the air motor section of the
pump.
GENERAL DESCRIPTION
The ARO diaphragm pump offers high volume delivery even
at low air pressure and a broad range of material compat-
ibility 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 dif-
ferential in the air chambers to alternately create suction and
positive fluid pressure in the fluid chambers, valve checks
insure a positive flow of fluid.
This diaphragm pump was developed to address the unique
problems associated with pumping dry powders, which can
“pack out” inside the pump fluid chambers, if not kept in a
semi-fluid state.
ꢂ
ꢂ
ꢂ
NOTE: When using air for powder fluidization, make sure
it is filtered and very dry.
This system incorporates the use of special valves to intro-
duce air or inert gas* into the fluid chambers simultaneously
to a pumping cycle in a timed sequence which keeps the
powder in a fluidized state during the transfer process.
THEORY OF OPERATION
The main air distribution valve (252) is a double pilot actu-
ated four-way valve. It is a slave to the pump major air valve.
The distribution valve recognizes the signal from two pump
major air valve (259) ports (air dumps). These signals are con-
verted into alternating output pressure distributions, which
are injected into the fluid chambers during the pumping cy-
cle to fluidize the powder as the diaphragm moves through
the discharge stroke.
INSTALLATION
WARNING THE PUMPING SYSTEM MUST BE GROUND-
ED TO PREVENT STATIC DISCHARGE. THIS INCLUDES
THE PUMP AND ALL INPUT AND OUTPUT SUPPLY
LINES AND RELATED SYSTEM DEVICES AND ACCESSO-
RIES. FAILURE TO DO SO CAN RESULT IN EXPLOSION
AND SERIOUS PERSONAL INJURY.
SYSTEM GROUNDING
Consult local building codes and electrical codes for
specific requirements.
ꢂ
ꢂ
ꢂ
Must comply with all applicable Local and National
codes for such applications.
The flow of air supplied to the fluid chamber is controlled by
the (248) filter / regulator. Under normal operating condi-
tions, this is the primary control.
Grounding is accomplished through the ground lug
and strap provided on the pump. Keep the grounding
strap as short as possible.
When air is supplied to the filter / regulator (248), the dis-
tribution valve directs the flow of air into the fluid chamber
that will dispense first for 3 to 8 seconds. The time delay then
supplies the start signal to open the main pump air supply
valve. When the pump diaphragm reaches the end of the
discharge stroke, it reverses direction. The distribution valve
then shifts and shuts off the fluidizing air to the first fluid
chamber as it applies a burst of air to the second fluid cham-
ber and fluidizes the powder in the second chamber.
The air induction orifice (76) increases the air velocity prior
to injection point because of the orifice and it prevents clog-
ging of the injector feed line.
NOTE: The restart valve (258) is a bleed valve which will stop
the pump and then restart the pump by re-initiating the time
delay cycle.
*NOTE: Use of other gases: Using only a gas to operate a 2”
pump can be rather expensive because of the high volume
needed. Separate air / gas inputs allow the fluidizing feature
of this pump to utilize special inert gas, such as Nitrogen or
Argon (air), if necessary and still allow use of standard com-
pressed shop air for the pumping function.
Safe operating conditions are the responsibility of the
installer and operator.
Secure the diaphragm pump legs to a suitable surface
to avoid damage by excessive vibration.
ꢂ
ꢂ
OPERATING INSTRUCTIONS
START-UP
NOTE: PRIOR TO START-UP, MAKE SURE THE GROUNDING
INSTRUCTIONS WERE FOLLOWED.
1. Connect air supply to (263) main air supply control valve
(30 - 40 p.s.i. / 2.1 - 2.8 bar).
2. Turn the air on.
3. Attach air (or gas) to (248) filter / regulator. CAUTION: Do
not apply excessive Fluidization Gas* Pressure (refer to
note under “General Description”).
4. At (248), turn on air (or inert gas) supply. There will be a
3 to 8 second time delay, during which the pump will be
fluidizing any powder left in the pump from an earlier
dispense. This time delay will occur on all start-ups.
The ability to introduce special gas also means special ma-
terials could be injected through the fluidization lines. Ap-
plications may include such materials as colorants, foaming
agents, additives, neutralizers, etc.
OPERATION AND ADJUSTMENT
NOTE: Powder type materials can vary in flow-ability and the
same settings may not work universally. Factors such as den-
sity and humidity can require changing the mixture of flow
rate and fluidization air and some experimenting should be
expected.
AIR AND LUBE REQUIREMENTS
WARNING EXCESSIVE AIR PRESSURE. Can cause pump
damage, personal injury or property damage. The
pump air supply must be limited to 50 p.s.i.g. (3.4 bar)
maximum inlet air pressure.
The air supply line or hose to the pump should be ad-
equately sized to carry a sufficient volume of air to the
pump. The material inlet supply tubing should not be too
IMPORTANT: DO NOT TURN FILTER / REGULATOR (248) OFF.
Positive air (or gas) pressure must be supplied to the filter /
regulator to allow the pump to function. Powder will accu-
mulate in the fluid caps if the pump is not allowed to expel
excess material before the pump shuts down. Restart can
ꢂ
PP20A-XXX-XXX (en)
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compress some powders to a solid that may cause the pump
to fail. The pump should cycle until most of the powder has
been purged before it is shut down.
SCHEMATIC CIRCUIT
Air / Nitrogen
4
2
Calibration procedure on initial start-up:
12
14
A212PD
NOTE: Once these parameters are established for your spe-
cific application, they should not need to be changed.
1. Turn the flow and pressure on the (248) filter / regulator
all the way up.
2. Slowly decrease pressure and flow until pump begins to
labor (work harder).
95077
119309-103
Left
2
CP10-B
CP10-B
2
Right 4
4
1
3. Increase pressure and flow back to a point where the
pump begins to run smoothly. This will optimize the air-
to-powder mix and will help to establish the most effi-
cient working parameters.
2
1
H254PS
94977
Exh 24130
Figure 2
3
If the pump should begin to cycle slowly (bog down), the
powder can be purged by depressing restart button. This will
stop the pump and restart the aeration cycle and allow time
to increase air flow to the aeration ports for proper material
movement.
TROUBLE SHOOTING
Product discharged from exhaust outlet.
Check for diaphragm rupture.
ꢂ
ꢂ
Check tightness of (14) diaphragm screw.
IMPORTANT
SHUT DOWN PROCEDURE - TO HELP PREVENT PACK-OUT
It is good operating practice to dry cycle the pump 5 - 10
seconds at the end of each dispense cycle. This can be ac-
complished by closing off the powder source at the suction
of the pump or pull wand from material. This will help clear
the pump chambers of any residual powder.
Motor blows air or stalls.
ꢂ
ꢂ
Check (176) check valve for damage or wear.
Check for restrictions in valve / exhaust.
Low output volume, erratic flow, or no flow.
Check air supply.
ꢂ
ꢂ
ꢂ
ꢂ
Check for plugged outlet hose.
NOTICE: Failure to insure proper fluidization can result in
internal parts breakage and pump failure.
Check for kinked (restrictive) outlet material hose.
Check for kinked (restrictive) or collapsed inlet material
hose.
MAINTENANCE
Refer to the part views and descriptions as provided on page
6 through 11 for parts identification and Service Kit informa-
tion.
Suction hose must be a non-collapsing type, conductive
and capable of pulling a high vacuum (up to 30” mer-
cury).
Check all joints on the inlet manifolds and suction con-
nections. Connection must be air tight.
Inspect the pump for solid objects lodged in the dia-
phragm chamber or the seat area.
ꢂ
ꢂ
ꢂ
Keep good records of service activity and include pump
in preventive maintenance program.
ꢂ
ꢂ
ꢂ
Certain ARO “Smart Parts” are indicated which should be
available for fast repair and reduction of down time.
Service kits are divided to service two separate dia-
phragm pump functions: 1. AIR SECTION, 2. FLUID SEC-
TION. The FLUID SECTION is divided further to match
typical part MATERIAL OPTIONS.
Provide a clean work surface to protect sensitive internal
moving parts from contamination from dirt and foreign
matter during service disassembly and reassembly.
Before disassembling, empty captured material in the
outlet manifold by turning the pump upside down to
drain material from the pump.
ꢂ
ꢂ
Loctite® and 242® are registered trademarks of Henkel Loctite Corporation ARO® is a registered trademark of Ingersoll-Rand Company
ꢂ
ꢂ
ꢂ
Santoprene® is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. 271™ is a trademark of Henkel Loctite Corporation
ꢂ
ꢂ
ꢂ
Lubriplate® is a registered trademark of Lubriplate Division (Fiske Brothers Refining Company)
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TYPICAL CROSS SECTION
Figure 3
PP20A-XXX-XXX (en)
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PARTS LIST / PP20A-XXX-XXX FLUID SECTION
637309-XX fluid section service kits include: Balls (item 22), diaphragms (item 7), and items 19, 70, 144, 175 (listed below) plus
items 174 and 94276 Lubriplate® FML-2 grease (page 8).
ꢃ
MATERIAL CODE
SEAT OPTIONS
PP20A-XXX-XXX
“21”
BALL OPTIONS
PP20A-XXX-XXX
(2-1/2” diameter)
[A]
[B]
[C]
= Aluminum
= Nitrile
= Carbon Steel
“22”
ꢃ
[Co] = Copper
-XXX Seat
-AXX 94328-A (4) [Sp]
-SXX 94353 (4) [SS]
Qty [Mtl]
-XXX Ball
-XAX 93358-A (4) [Sp]
-XMX 93358-M (4) [MSp]
Qty [Mtl]
[MSp] = Medical Grade Santoprene
[Sp] = Santoprene
[SS] = Stainless Steel
[T]
= PTFE
DIAPHRAGM OPTIONS PP20A-XXX-XXX
(1/8” x 3-5/8” o.d.)
Service Kit
“7”
“19”
ꢃ
ꢃ
ꢃ
-XX = (Ball)
-XXX -XX = (Diaphragm) Diaphragm Qty [Mtl] “O” Ring
Qty [Mtl]
-XXA 637309-XA
-XXM 637309-XM
94329-A
94329-M
(2) [Sp] - - - - -
(2) [MSp] Y328-237
- - -
(4)
- - -
[T]
MANIFOLD CONNECTION / FLUID CAP MATERIAL OPTIONS PP20A-XXX-XXX
Aluminum
Stainless Steel
BSP
N.P.T.
BSP
N.P.T.
Tri-Clamp
PP20A-AAX-XXX PP20A-BAX-XXX PP20A-ASX-XXX PP20A-BSX-XXX PP20A-CSX-XXX
Qty Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl]
(size)
Item Description
Diaphragm Washer
15 Fluid Cap
6
(2) 96503
(2) 94769
(1) 94911
(1) 94767
(2) Y17-128
(2) - - - - -
[A] 96503
[A] 94769
[A] 94911-2
[A] 94767-2
[A] - - - - -
[A] 94357-2 [SS] 94357-2 [SS] 94357-2 [SS]
[A] 95556
[A] 95537-1 [SS] 95537-2 [SS] 96667
[A] 95536-1 [SS] 95536-2 [SS] 96666
- - - - - - - -
[A] - - - - -
[SS] 95556
[SS] 95556
[SS]
[SS]
[SS]
- - -
60 Inlet Manifold
61 Outlet Manifold
(2 - 11-1/2 N.P.T.)
Pipe Plug
- - - - - - - -
- - - - - - - -
- - - - - - - -
- - - - - - - -
63
(R-2, 2 - 11 BSP)
- - - 94439-2
- - -
EXTERNAL HARDWARE OPTIONS PP20A-XXX-XXX
Plated Steel
Stainless Steel
PP20A-XXP-XXX PP20A-XXS-XXX
(size)
Item Description
Qty Part No. [Mtl] Part No. [Mtl]
(M10 x 1.5 - 6g x 35 mm)
26 Screw
27 Screw
29 Nut
(8) 94409-1
(16) 94990-1
(16) 94992-1
[C] 94409-2 [SS]
(M10 x 1.5 - 6g x 45 mm)
[C] 94990
[C] 94992
[SS]
[SS]
(M10 x 1.5 - 6h)
PARTS LIST
(size)
(size)
Item Description
Qty Part No.
(1) 94358
(2) 96503
(2) 93065
(2) Y5-111-T
(1) 94324-4
(1) 94324-5
(2) 94100
[Mtl]
Item Description
Qty Part No.
(1) Y17-51-N
(1) 94829
[Mtl]
[C]
- - -
[C]
[B]
[B]
(1/4 - 18 N.P.T. x 7/16”)
1
5
9
Rod
[C]
[A]
74 Pipe Plug
79 Ground Kit Assembly
(not shown)
Back-Up Washer
Washer
(M10 x 1.5 - 6g x 120 mm)
[SS]
[SS]
[A]
131 Screw
(4) 94531
(5/8” - 18 x 2-1/2”)
(3/16” x 1-3/8” o.d.)
14 Screw
68 Air Cap
69 Air Cap
70 Gasket
144 “U” Cup
175 “O” Ring
(2) Y186-51
(2) Y325-117
(4) 94098
ꢃ
(3/32” x 1” o.d.)
ꢃ
(0.406” i.d. x 0.031” thick)
[A]
180 Washer
[Co]
(1/4” - 14 x 1/2”)
[B]
250 Screw, Self-Tapping
(1) Y334-104-C [C]
ꢃ
FLUID SECTION DISASSEMBLY
FLUID SECTION REASSEMBLY
1. Remove (61) outlet manifold and (60) inlet manifold.
Reassemble in reverse order. Refer to the torque require-
ꢂ
ꢂ
ꢂ
2. Remove (22) balls, (19) “O” rings (if applicable) and (21)
seats.
ments on page 7.
Clean and inspect all parts. Replace worn or damaged
parts with new parts as required.
Lubricate (1) diaphragm rod and (144) “U” cups with Lu-
briplate FML-2 grease (94276 grease packet is included in
service kit).
3. Remove (15) fluid caps.
4. Remove the (6) diaphragm washer, (7) diaphragm and (5)
back-up washer.
NOTE: Do not scratch or mar the surface of (1) diaphragm rod.
Re-check torque settings after pump has been re-started
and run a while.
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PARTS LIST / PP20A-XXX-XXX FLUID SECTION
FOR THE AIR MOTOR
SECTION, SEE PAGES
3
2
1
4
74
ꢄ
8 & 9.
5
7
8
6
61 (PP20A-CSX-XXX)
74
ꢄ
Torque Sequence
61 (PP20A-XSX-XXX)
63
74
ꢄ
ꢄ
61 (PP20A-XAX-XXX)
26 ꢀꢀ
68
144
ꢁ
ꢁ
144
29
ꢀ
69
5
7
6
14 ꢀꢃ
22
21
19
ꢁ
27 ꢀꢀ
ꢁ
175 70
ꢁ
ꢁ
175
70
ꢁ
15
1
ꢁ
180 131 ꢀꢂ
9
22
21
63
ꢄ
60 (PP20A-XAX-XXX)
(PP20A-XSX-XXX)
26 ꢀꢀ
19
ꢁ
250
Figure 4
60 (PP20A-CSX-XXX)
TORQUE REQUIREMENTS
LUBRICATION / SEALANTS
ꢄ
ꢅ
Apply PTFE tape to threads.
NOTE: DO NOT OVERTIGHTEN FASTENERS.
ꢆ
ꢇ
ꢈ
ꢉ
(14) diaphragm screws, 65 - 70 ft lbs (88.1 - 94.9 Nm).
(26) screws, 30 - 40 ft lbs (40.7 - 54.2 Nm).
(27) screws, 30 - 40 ft lbs (40.7 - 54.2 Nm).
(131) screws, 35 - 40 ft lbs (47.5 - 54.2 Nm).
Apply Loctite® 242® to threads at assembly.
Apply Loctite 271™ to threads at assembly.
Apply Lubriplate FML-2 grease (94276) to all “O” rings, “U” cups and
mating parts.
Apply anti-seize compound to threads and bolt and nut flange heads
which contact pump case when using stainless steel fasteners.
ꢊ
PP20A-XXX-XXX (en)
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PARTS LIST / PP20A-XXX-XXX AIR MOTOR SECTION
Indicates parts included in 637421 air section repair kit, plus items 70, 144, 175 and 180 (page 6).
ꢋ
AIR MOTOR PARTS LIST
(size)
(size)
Item Description
(Qty) Part No.
(1) 94028
(1) 95955
(4) 95887
(1) 95651
(2) 94083
(2) 94084
(2) Y29-42-S
(1) 94099
[Mtl]
Item Description
(Qty) Part No.
(1) Y240-9
(1) 94081
(1) Y325-119
(1) Y325-22
(2) Y325-26
(2) Y325-202
(2) 94102
(1) 95666
(1) 95665
(1) 94117
(2) Y325-105
(1) 96347
[Mtl]
[B]
[Br]
[B]
[B]
[B]
[B]
[Sp]
[B]
[B]
[C]
[B]
[A]
[SS]
[B]
[B]
[B]
[B]
[C]
(1/8" x 7/8" o.d.)
101 Center Body
103 Bushing
[A]
169 “U” Cup
170 Piston Sleeve
171 “O” Ring
172 “O” Ring
173 “O” Ring
174 “O” Ring
176 Diaphragm
199 Track Gasket
200 Gasket
[Bz]
[SS]
[D]
[SS]
[D]
(M6 x 1 - 6g x 20 mm)
(3/32” x 1-1/8” o.d.)
105 Screw
111 Spool
ꢋ
ꢋ
ꢋ
ꢋ
ꢋ
ꢋ
ꢋ
(1/16” x 1-1/8” o.d.)
(1/16” x 1-3/8” o.d.)
(1/8” x 1/2” o.d.)
(check valve)
(0.250” x 2.276” long)
118 Actuator Pin
121 Sleeve
(1/4” - 20 x 1/4”)
128 Set Screw
132 Gasket
[SS]
[B]
ꢋ
(1/4”)
133 Lockwasher
134 Screw
(4) Y117-416-C [C]
(M6 x 1 - 6g x 30 mm)
(4) 96358
(1) 96346
(1) 96335
(1) Y325-32
(1) 95966
(1) Y186-50
(1) 95650
(1) 95659
(1) 94026
(1) 67164
(2) 94433
[SS]
[A]
[A]
[B]
[B]
201 Muffler
231 “O” Ring
233 Adapter Plate
(3/32” x 11/32” o.d.)
135 Valve Housing
136 Plug
(1/16” x 2” o.d.)
(M6 x 1 - 6g x 16 mm)
137 “O” Ring
138 “U” Cup
139 “U” Cup
240 Screw
(2) 95991
(1) 96344
ꢋ
ꢋ
ꢋ
(3/16” x 1.792” o.d.)
(3/16” x 1-1/4” o.d.)
241 Track Gasket
ꢋ
ꢋ
ꢋ
ꢋ
(1/16” x 7/32” o.d.)
[B]
242 “O” Ring
243 “O” Ring
244 “O” Ring
255 Pipe Plug
(1) Y325-5
(1) Y325-204
(1) Y325-208
(2) Y227-1-L
(1) 94276
(1/8” x 5/8” o.d.)
140 Valve Insert
141 Valve Plate
166 Track Gasket
[Ck]
[Ck]
[B]
[D]
[U]
(1/8” x 7/8” o.d.)
(1/16 - 27 N.P.T. x 1/4”)
ꢋ
ꢋ
(includes 168 and 169)
167 Pilot Piston
Lubriplate FML-2 Grease
Lubriplate Grease, 10 Pack
ꢋ
(3/32” x 5/8” o.d.)
168 “O” Ring
637308
MATERIAL CODE
3. Install new (168) “O” rings and (169) seal - Note the lip di-
rection. Lubricate and replace (167) pilot piston.
4. Reassemble remaining parts. Replace (173 and 174) “O”
rings.
[A] = Aluminum
[C] = Carbon Steel
[Ck] = Ceramic
[D] = Acetal
[SS] = Stainless Steel
[U] = Polyurethane
[B] = Nitrile
[Br] = Brass
[Bz] = Bronze
[Sp] = Santoprene
AIR MOTOR SECTION SERVICE
Service is divided into two parts - 1. Pilot Valve, 2. Major
MAJOR VALVE DISASSEMBLY
1. Remove (135) valve block and (233) adapter plate, expos-
ing (166 and 132) gaskets and (176) checks.
2. Remove (233) adapter plate, releasing (140) valve insert,
(141) valve plate, (199, 200 and 241) gaskets and (231,
243 and 244) “O”rings.
3. Remove (136) plug and (137) “O” ring, releasing (111)
spool.
Valve.
GENERAL REASSEMBLY NOTES:
Air motor section service is continued from fluid section
repair.
ꢂ
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.
ꢂ
Take precautions to prevent cutting “O” rings upon instal-
lation.
Lubricate “O”rings with Lubriplate FML-2 grease.
Do not over-tighten fasteners, refer to torque specifica-
tion block on view.
ꢂ
MAJOR VALVE REASSEMBLY
1. Install new (138 and 139) “U” cups on (111) spool - LIPS
ꢂ
ꢂ
MUST FACE EACH OTHER.
2. Insert (111) spool into (135) valve housing.
3. Install (137 and 242) “O” rings on (136) plug and assemble
plug to (135) valve housing, securing with (105) screws.
4. Install (140) valve insert, (141) valve plate, (199) gasket
and (231, 243 and 244) “O” rings into (135) valve hous-
ing. NOTE: Assemble (140) valve insert with “dished” side
toward (141) valve plate. Assemble (141) valve plate with
part number identification toward (140) valve insert.
5. Assemble (200 and 241) gaskets and (233) adapter plate
to (135) valve housing, securing with (240) screws. NOTE:
Tighten screws to 40 - 50 in. lbs (4.5 - 5.6 Nm).
6. Assemble (132 and 166) gaskets and (176) checks to (101)
center body.
7. Assemble (135) valve housing and components to (101)
center body, securing with (134) screws. NOTE: Tighten
screws to 40 - 50 in. lbs (4.5 - 5.6 Nm).
Re-torque fasteners following re-start.
Service Tools - To aid in the installation of (168) “O” rings
onto the (167) pilot piston, use tool #204130-T, available
from ARO.
ꢂ
ꢂ
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.
PILOT VALVE REASSEMBLY
1. Clean and lubricate parts not being replaced from service
kit.
2. Install new (171 and 172) “O”rings. Replace (170) sleeve.
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PARTS LIST / PP20A-XXX-XXX AIR MOTOR SECTION
PILOT VALVE PART GROUP
118 ꢁ 169 168 ꢁ
172 ꢁ
171 ꢁ
170
121
ꢁ 174
ꢁ 173
167
ꢃ 255
ꢁ 243
ꢁ 231
173 ꢁ
121
140 ꢁ 199
244 ꢁ 233 240 ꢀ 166 ꢁ
118
135
133
174 ꢁ
103
101
201
ꢁ 141 ꢁ 200 ꢁ 241 ꢃ 128 231 ꢁ 255 ꢅ 132 ꢁ 176 ꢁ
ꢆ 134
138 ꢁ
111
139 ꢁ
137 ꢁ
242
128 ꢃ
136
Figure 5
ꢄTORQUE REQUIREMENTS ꢅ
105 ꢀ
MAJOR VALVE
NOTE: DO NOT OVERTIGHTEN FASTENERS.
ALL FASTENERS ARE METRIC.
(105) screw, 40 - 50 in. lbs (4.5 - 5.6 Nm).
(134) screw, 40 - 50 in. lbs (4.5 - 5.6 Nm).
(240) screw, 40 - 50 in. lbs (4.5 - 5.6 Nm).
LUBRICATION / SEALANTS
ꢉ
ꢈ
Apply Lubriplate FML-2 grease to all “O” rings, “U” cups and mating parts.
Apply Loctite 271 to threads at assembly.
PP20A-XXX-XXX (en)
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PARTS LIST / PP20A-XXX-XXX CONTROL SECTION
AIR CONTROL PARTS LIST
(size)
(size)
Item Description
(Qty) Part No.
Item Description
(Qty) Part No.
(1) H254PS
(1) 94977
(1/8 - 27 N.P.T.F. - 1)
76 Adapter
77 Elbow
(2) 94817
263 Control Valve
(1/4” o.d. tube x 1/8 - 27 N.P.T.)
with 0.078” orifice (1/2 - 14 N.P.T.)
(2) 59756-56
264 Pipe Plug
(1/4” o.d. x 14”)
(1/2 - 14 N.P.T.F. - 1 x 1-1/8”)
78 Tube
245 Air Line Connection Kit
(2) 59675-(
(1) 67223
(1) 59629
(1) 29850
(1) P29122-100
(1) 1950
)
265 Nipple
(1) Y27-4-C
(1) Y45-9-C
ꢌ
(not shown)
(1/8 N.P.T.F. male x #10 - 32 female)
(3/4 - 14 N.P.T. x 1/2 - 14 N.P.T.)
266 Reducing Bushing
(1/4” o.d. x 27”)
246 Adapter
267 Tube
268 Tube
269 Tube
270 Tube
(1) 59675-(
(2) 59675-(
(1) 94981-(
(1) 94981-(
)
)
)
)
ꢌ
ꢌ
ꢍ
ꢍ
(0 - 160 p.s.i. / 0 - 11 bar)
(1/4” o.d. x 2”)
247 Gauge
(5/32” o.d. x 9”)
248 Piggyback Filter / Regulator
(1/4 - 18 N.P.T.F. - 1 x 1-5/16”)
(5/32” o.d. x 7-1/2”)
249 Nipple
(1/4” o.d. tube x 1/4 - 18 N.P.T.)
251 Restrictor
252 Alpha Valve, 4-Way
253 Flow Control
(1) 95077
271 Elbow
272 Screw
273 Nut
(2) 59756-156
(3) Y19-113-C
(3) Y22-10-C
(3) Y14-10-C
(2) Y6-55-C
(2) Y117-516
(2) Y12-5-C
(2) Y13-4-C
(#10 - 24 x 1-1/4”)
(#10)
(1) A212PD
(1) 119309-103
(1) 59765-4
(5) 59474-56
(1) 94812
(1/4” o.d. tube x #10 - 32)
(#10 - 24)
(1/4” o.d. tube x 5/32” o.d. tube)
254 Reducer
274 Lock Washer
(1/4” o.d. tube x 1/8 - 27 N.P.T.)
(5/16” - 18 x 1”)
256 Connector
275 Screw
(1/8 - 27 P.T.F.)
(5/16”)
257 Adapter
276 Lock Washer
(1/8 - 27 N.P.T.F.)
(5/16” - 18)
258 Button Bleed Valve
(1) 24130
277 Nut
(5/32” o.d. tube x 1/8 - 27 N.P.T.)
(1/4”)
259 Elbow
(4) 59756-4
(2) CP10-B
(1) 95174
278 Washer
260 Check Valve
261 Bracket
262 Pipe Plug
(1/4” o.d. x 100’)
(5/32” o.d. x 100’)
Bulk Tubing
Bulk Tubing
(1) 59675-100
(1) 94981-100
ꢌ
ꢍ
(1/4 - 18 N.P.T. x 7/16”)
(2) Y17-51-N
VIEW A-A
256 260 256 262
254
253
246
248
272
271
274
252
273
251 247 249 259
Figure 6
PP20A-XXX-XXX (en)
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PARTS LIST / PP20A-XXX-XXX CONTROL SECTION
261
268 (2”long)
256
See view “A-A”
(14”long) 78
(7.5”long) 270
259
260
256
277
266
276
265
278
258
275
257
269 (9”long)
259
256
264
78 (14”long)
263
76
77
76
(27”long) 267
Figure 7
Page 11 of 12
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DIMENSIONAL DATA
Dimensions shown are for reference only. They are displayed in inches and millimeters (mm).
PP20A-XSX-XXX (outlet this side)
2 - 11-1/2 N.P.T.F. - 1 (PP20A-AXX-XXX)
Rp 2 (2 - 11 BSP parallel) (PP20A-BXX-XXX)
2-1/2”Tri-Clamp (PP20A-CXX-XXX)
E
F
L
Air Inlet 1/2 - 14 N.P.T.F.
L
Outlet
B
G
N
M
D
Inlet
K
H
C
J
A
Exhaust Port 1-1/2 - 11-1/2 N.P.T.
DIMENSIONS
A - see below
B - 24-3/4” (628.7 mm)
C - 10-1/16” (255.6 mm) G - 26-1/4” (666.8 mm)
D - see below
E - 16-3/32” (408.5 mm) H - 9-1/16" (230.2 mm)
L - see below
F - 12” (304.8 mm)
J - 10-1/16” (255.6 mm) M - see below
K - 9/16” (14.3 mm)
N - see below
Pump Model
“A”
"D"
"L"
"M"
"N"
PP20A-XAX-XXX
PP20A-XSX-XXX
PP20A-CSX-XXX
21-3/8" (542.3 mm)
21-3/16" (537.7 mm)
21-3/16" (537.7 mm)
1-7/8" (47.6 mm)
2-1/2" (63.5 mm)
2-1/2" (63.5 mm)
2" (50.8 mm)
2-3/32" (53.0 mm)
3" (76.2 mm)
14-5/8" (371.2 mm)
15-1/4" (387.1 mm)
15-1/4" (387.1 mm)
20-5/32" (512.0 mm)
20-25/32" (527.8 mm)
20-25/32" (527.8 mm)
Figure 8
PN 97999-1136
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