Ingersoll Rand Water Pump PD05P XXX XXX User Manual

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 . . . . . . . . . . . . . 3/32dia. (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)  
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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  
valvebe 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”  


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-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 (  
)
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Yellow (  
)
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( ) 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  
62 ꢁꢂ  
15  
43  
22  
26 ꢁꢂ  
60 (models PD05P-ASS-XXX)  
63  
12  
21  
19  
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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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.  
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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 “Oring 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 “Orings.  
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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), “Oring 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) “Orings.  
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) “Oring 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.  
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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  
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)Oring 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 “Orings 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 “Orings for wear.  
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Check “Ucups 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) “Orings 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  
Page 8 of 8  
PD05P-XXX-XXX (en)  
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