OPERATOR’S MANUAL
PD10E-X-X
RELEASED:
REVISED:
(REV. 03)
6-15-05
5-25-09
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
1” DIAPHRAGM PUMP
1:1 RATIO (CONDUCTIVE NON-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.
637397 for air section repair (see page 6).
637396-XX for fluid section repair (see page 4). NOTE: This
kit also contains several air motor seals which will need to be
replaced
.
637395-7 major air valve assembly (see page 7).
PUMP DATA
Models . . . . . . see Model Description Chart for “-XXX”.
Pump Type . . . Non-Metallic Air Operated Double Diaphragm
Material . . . . . see Model Description Chart.
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.41 lbs (9.26 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) . . . 53.0 g.p.m. (200.6 l.p.m.)
Displacement / Cycle @ 100 p.s.i.g. . . 0.226 gal. (0.86 lit.)
Maximum Particle Size . . . . . . . . . . . . 1/8”dia. (3.2 mm)
Maximum Temperature Limits (diaphragm / ball / seal material)
E.P.R. / EPDM. . . . . . . . . . . . . . . . -600 to 2800 F (-510 to 1380 C)
Hytrel . . . . . . . . . . . . . . . . . . . . . -200 to 1500 F (-29º to 660 C)
Nitrile . . . . . . . . . . . . . . . . . . . . . . 100 to 1800 F (-12º to 820 C)
Polypropylene . . . . . . . . . . . . . . 350 to 1750 F (20 to 790 C)
Santoprene . . . . . . . . . . . . . . . -400 to 2250 F (-400 to 1070 C)
T.F.E. Teflon . . . . . . . . . . . . . . . 400 to 2250 F (40 to 1070 C)
Viton . . . . . . . . . . . . . . . . . . . . . -400 to 3500 F (-400 to 1700 C)
Dimensional Data . . . . . . . . . . . . . . . . see page 8
PD10E-FES-PXX
Figure 1
MODEL DESCRIPTION CHART
PD10E - F E S - P X X
Center Section Material
- Conductive Polypropylene
E
Fluid Connection / Location
- 1" A.N.S.I. / DIN Flange / End
F
Fluid Caps & Manifold Material
- Conductive Polypropylene
E
Hardware Material
- Stainless Steel
S
Mounting Dimension . . . . . 5.032”x 10.050”(127.8 mm x 255.3 mm)
Noise Level @ 70 p.s.i., 50 c.p.m. . . . . . 85.0 db(A)
Seat Material
- Polypropylene
P
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.
Ball Material
- Santoprene
C - Hytrel
G - Nitrile
A
T
- T.F.E. (Teꢀon)
V - Viton
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.
Diaphragm Material
A
- Santoprene
T
- T.F.E. (Teꢀon) / Santoprene
C - Hytrel
G - Nitrile
V - Viton
FLUID SECTION SERVICE KIT SELECTION
PD10E - FES - P X X
EXAMPLE: Model # PD10E-FES-PAA
Fluid Section Service Kit # 637396-AA
637396 - X
Ball
X
Diaphragm
INGERSOLL RAND COMPANY LTD
P.O. BOX 151 ONE ARO CENTER BRYAN, OHIO 43506-0151
© 2009
CCN 15244940
(800) 276-4658 FAX (800) 266-7016
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GENERAL DESCRIPTION
OPERATING INSTRUCTIONS
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.
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
inactive for a few hours.
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, 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 pressure and will stop cycling once maxi-
mum line pressure is reached (dispensing device closed) and
will resume pumping as needed.
PARTS AND SERVICE KITS
Refer to the part views and descriptions as provided on page 4
through 7 for parts identification and Service Kit information.
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 diaphragm
pump functions: 1. AIR SECTION, 2. FLUID SECTION. The Fluid
Section is divided further to match typical part Material
Options.
AIR AND LUBE REQUIREMENTS
MAINTENANCE
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.
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.
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 pump
in preventive maintenance program.
Before disassembling, empty captured material in the
outlet manifold by turning the pump upside down to
drain material from the pump.
FLUID SECTION DISASSEMBLY
INSTALLATION
1. Remove (60) outlet manifold, (61) inlet manifold.
2. Remove (22) balls, (19 and 33) “O”rings and (21) seats.
3. Remove (15) fluid caps.
NOTE: Only Teflon diaphragm models use a primary diaphragm (7)
and a backup diaphragm (8). Refer to the auxiliary view in the Fluid
Section illustration.
4. Remove the (6) diaphragm washer, (7) or (7 / 8) diaphragms,
and (5) backup washer.
NOTE: Do not scratch or mar the surface of (1) diaphragm rod.
Verify correct model / configuration prior to installation.
Retorque all external fasteners per specifications prior to
start up.
Pumps are tested in water at assembly. Flush pump with
compatible fluid prior to installation.
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.
Material supply tubing should be at least the same diam-
eter as the pump inlet manifold connection.
Material supply hose must be reinforced, non-collapsible
type compatible with the material being pumped.
Piping must be adequately supported. Do not use the
pump to support the piping.
Use flexible connections (such as hose) at the suction
and discharge. These connections should not be rigid
piped and must be compatible with the material being
pumped.
Secure the diaphragm pump legs to a suitable surface
(level and flat) to insure against damage by vibration.
Pumps that need to be submersed must have both wet
and non-wet components compatible with the material
being pumped.
Submersed pumps must have exhaust pipe above liquid
level. Exhaust hose must be conductive and grounded.
Flooded suction inlet pressure must not exceed 10 p.s.i.g. (0.69
bar).
FLUID SECTION REASSEMBLY
Reassemble in reverse order. Refer to the torque requirements
on page 5.
Clean and inspect all parts. Replace worn or damaged parts
with new parts as required.
Lubricate (1) diaphragm rod and (144) “U” cup with Lubri-
plate FML-2 grease (94276 grease packet is included in ser-
vice kit).
For models with Teflon diaphragms: Item (8) Santoprene
diaphragm is installed with the side marked “AIR SIDE”
towards the pump center body. Install the Teflon diaphragm
(7) with the side marked “FLUID SIDE” towards the (15) fluid
cap.
Re-check torque settings after pump has been re-started
and run a while.
Viton , Teflon and Hytrel are registered trademarks of the DuPont Company Loctite is a registered trademark of Henkel Loctite Corporation
®
®
®
®
®
Santoprene is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. Lubriplate is a registered trademark of Lubriplate Division (Fiske Brothers Refining Company)
®
®
PD10E-X-X (en)
Page 3 of 8
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PARTS LIST / PD10E-X-X FLUID SECTION
FLUID SECTION SERVICE KITS (637396-XX)
KITS INCLUDE: BALLS (see Ball Option, refer to -XX in Service Kit chart below), DIAPHRAGMS (see Diaphragm Option, refer to -XX in
Service Kit chart below), and items 19, 33, 70, 1ꢀꢀ, 175 and 180 (listed below) plus 17ꢀ and 9ꢀ276 Lubriplate FML-2 grease (page 6).
SEAT OPTIONS
PD10E-FES-XXX
BALL OPTIONS
PD10E-FES-XXX
MATERIAL CODE
= Nitrile
[C] = Carbon Steel
[Co] = Copper
[E] = E.P.R.
[GP] = Groundable Polypropylene
[H] = Hytrel
[P] = Polypropylene
[SP] = Santoprene
[SS] = Stainless Steel
[T] = T.F.E. (Teflon)
[V] = Viton
[B]
“21”
“22” (2-1/ꢀ” dia.)
-XXX Seat
Qty [Mtl]
[P]
-XXX Ball
Qty
[Mtl]
-PXX 9ꢀ707-1 (ꢀ)
-XAX 93278-A (ꢀ)
-XCX 93278-C (ꢀ)
-XGX 93278-2 (ꢀ)
-XTX 93278-ꢀ (ꢀ)
-XVX 93278-3 (ꢀ)
[SP]
[H]
[B]
[T]
[V]
DIAPHRAGM OPTIONS PD10E-FES-XXX
SERVICE KIT
“7”
“8”
“19”
“33”
-XX = (Ball)
-XX = (Diaphragm) Diaphragm Qty [Mtl] Diaphragm Qty [Mtl]
“O” Ring
“O” Ring
(1/8” x 2-1/8” o.d.)
(1/8” x 1-5/8” o.d.)
Qty [Mtl]
Qty
(ꢀ)
[Mtl]
[E]
-XXX
-XXA 637396-XA
-XXC 637396-XC
-XXG 637396-XG
-XXT 637396-XT
-XXV 637396-XV
96267-A
96267-C
96267-G
961ꢀ6-T
95989-3
(2)
(2)
(2)
(2)
(2)
[SP] -----
[H] -----
---
---
---
--- 93280
(ꢀ)
(ꢀ)
(ꢀ)
(ꢀ)
(ꢀ)
[E] 93279
[V] Y327-220
--- Y327-225
--- Y325-225
(ꢀ)
(ꢀ)
(ꢀ)
(ꢀ)
[V]
[B]
[T]
[V]
[B] -----
[B] Y325-220
[T] 93281
[T] 961ꢀ5-A
[V] -----
(2) [SP] 93282
--- --- Y327-225
[V] Y327-220
COMMON PARTS
Item Description (size)
Qty
Part No.
95995
[Mtl]
Item
Description (size)
Qty
(1)
(1)
(1)
(2)
Part No.
9619ꢀ-3
9610ꢀ-5
9610ꢀ-6
958ꢀ3
[Mtl]
[GP]
[GP]
[GP]
[SS]
[B]
1
5
6
Rod
(1)
(2)
[C]
61 Outlet Manifold
68 Air Cap
Backup Washer
Diaphragm Screw
95990-1
96108-1
96105-3
95880
[SS]
[P]
(2)
69 Air Cap
15 Fluid Cap
(2)
[GP]
[SS]
[SS]
[SS]
[SS]
[Co]
[GP]
70 Gasket
(M8 x 1.25 - 6g x 30 mm)
(M8 x 1.25 - 6g x 100 mm)
26 Screw
27 Screw
28 Washer
(16)
(28)
(ꢀꢀ)
(28)
(1)
131 Screw
(ꢀ)
(2)
(2)
(8)
(ꢀ)
96216
(M8 x 1.25 - 6g x 50 mm)
(3/16” x 1-1/8” o.d.)
96163
1ꢀꢀ "U” Cup
175 "O” Ring
180 "O” Ring
Y186-ꢀ9
Y325-11ꢀ
96292
[B]
(8.5 mm i.d.)
(3/32” x 13/16” o.d.)
(2.5 mm x 12 mm o.d.)
(M8 x 1.25 - 6h)
96217
[Co]
[SS]
[SS]
(M8 x 1.25 - 6h)
29 Flange Nut
(see page 7)
ꢀ3 Ground Lug
96229
9300ꢀ
195 Hex Flange Nut
95879
60 Inlet Manifold
(1)
96195-3
Air Section Service Kit parts, see page 6.
Page ꢀ of 8
PD10E-X-X (en)
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PARTS LIST / PD10E-X-X FLUID SECTION
3
1
5
7
8
6
9
10
2
4
Torque Sequence
COLOR CODE
DIAPHRAGM
COLOR
FOR THE
AIR MOTOR SECTION
SEE PAGES 6 & 7
BALL
COLOR
MATERIAL
Hytrel
Nitrile
Cream
Black
Tan
Cream
Red ( )
Tan
Santoprene
Santoprene
(Backup)
T.F.E. (Teꢀon)
Viton
26
61
Green
N / A
White
Yellow (-)
(-) Dash
White
Yellow ( )
( ) Dot
68
A
A
131
70
144
70
69
27
7
22
19
21
33
29
144
175
175
15
22
19
21
33
180 195
1
5
6
26
60
Figure 2
TORQUE REQUIREMENTS
NOTE: DO NOT OVERTIGHTEN FASTENERS.
ALL FASTENERS ARE METRIC.
(6) Diaphragm washer, 25 - 30 ftlbs (33.9 - 40.7 Nm), lubri-
cate face with Lubriplate grease and apply Loctite
271 to threads.
(26) Screws, 10 - 12 ft lbs (13.6 - 16.3 Nm).
(29) Nuts, 10 - 12 ft lbs (13.6 - 16.3 Nm).
(131) Screws, tighten to 11 - 14 ft lbs (14.9 - 19.0 Nm).
VIEW OF TWO PIECE TEFLON DIAPHRAGM
AUXILIARY VIEW A-A
LUBRICATION / SEALANTS
Apply Lubriplate FML-2 grease to all “O" rings, ”U"
cups & mating parts.
Apply Loctite 242 to threads at assembly.
Apply anti-seize compound to threads and bolt and
nut ꢀange heads which contact pump case when
using stainless steel fasteners.
180
28
Santoprene 8
7 Teꢀon
Lubriplate FML-2 is a white food grade petroleum grease.
PD10E-X-X (en)
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PARTS LIST / PD10E-X-X AIR SECTION
Indicates parts included in 637397 Air Section Service Kit shown below and items (70), (1ꢀꢀ), (175) and (180) shown on page ꢀ.
AIR MOTOR PARTS
Item Description (size)
101 Center Body
103 Bushing
Qty
Part No.
[Mtl]
[GP]
[D]
Item Description (size)
Qty Part No. [Mtl]
1/8” x 7/8” o.d.)
169 "U” Cup (
(1) 95970-1
(1) 96000
(ꢀ) 95886
(2) 958ꢀ0
(1) 96293
(2) 95999
(2) 95123
(1) 96170
(5) 95931
(6) 95887
(1) 9617ꢀ-3
(1) 95833
(1) 958ꢀꢀ
(1) Y325-32
(1) Y2ꢀ0-9
(1) 9ꢀ081
[B]
170 Piston Sleeve
[Br]
(M6 x 1 - 6g x 180 mm)
(3/32” x 1-1/8” o.d.)
105 Screw
[SS]
[SS]
[D]
171 "O” Ring
172 "O” Ring
173 "O” Ring
17ꢀ "O” Ring
(1) Y325-119 [B]
(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)
107 End Plate
111 Spool
(1) Y325-22
(2) Y325-26
[B]
[B]
118 Actuator Pin
121 Sleeve
[SS]
[D]
(2) Y325-202 [B]
(2) 9ꢀ102 [SP]
(ꢀ) Y178-52-S [B]
176 Diaphragm
(5/32” o.d. x 1/2” long)
132 Gasket
[B]
181 Roll Pin
(M6)
133 Washer
[B]
200 Gasket
(1) 958ꢀ2
(1) 350-568
(1) 95832
(ꢀ) 9592ꢀ
(1) 9ꢀ276
637308
[B]
(M6 x 1 - 6g x 20 mm)
13ꢀ Screw
[SS]
[SS]
[GP]
[P]
201 Muffler
135 Valve Block
136 End Cap
137 Gasket
233 Adapter Plate
[B]
(M6 x 1 - 6h)
236 Nut
[SS]
Lubriplate FML-2 Grease
(3/16” x 1-5/8” o.d.)
138 "U” Cup
139 "U” Cup
[B]
Lubriplate Grease Packets (10)
(3/16” x 1-1/8” o.d)
(1) Y186-ꢀ9
(1) 95838
(1) 95885
[B]
[AO]
[AO]
1ꢀ0 Valve Insert
1ꢀ1 Valve Plate
MATERIAL CODE
[P] = Polypropylene
[SP] = Santoprene
[SS] = Stainless Steel
[U] = Polyurethane
[AO] = Alumina Oxide
[B] = Nitrile
[Br] = Brass
[D] = Acetal
[GP] = Groundable Polypropylene
166 Gasket
(1) 96171
(1) 6716ꢀ
(2) 9ꢀꢀ33
(1) 9ꢀ026
[B]
[D]
[U]
[B]
(includes 168 and 169)
167 Pilot Piston
(3/32” x 5/8” o.d.)
168 "O” Ring
(includes 168 and 169)
167 Pilot Piston
Fluid Section Service Kit, 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, expos-
ing (132 and 166) gaskets and (176) checks.
2. Insert a small flat blade screwdriver into the notch
in the side of (135) valve block and push in on tab
to remove (233) adapter plate, releasing (140) valve
insert, (141) valve plate and (200) gasket.
Air Motor Section Service is continued from Fluid Section repair.
Inspect and replace old parts with new parts as necessary. Look
for deep scratches on surfaces, and nicks or cuts in “O”rings.
Take precautions to prevent cutting “O” rings upon installa-
tion.
Lubricate “O”rings with Lubriplate FML-2 grease.
Do not over-tighten fasteners, refer to torque specification
block on view.
3. Remove (136) end cap and (137) “O” ring, releasing (111)
spool.
MAJOR VALVE REASSEMBLY
Re-torque fasteners following restart.
SERVICE TOOLS − To aid in the installation of (168) “O” rings onto
the (167) pilot piston, use tool # 204130-T, available from ARO.
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) gasket on (136) end cap and assemble
end cap to (135) valve block, securing with (107)
end plates and (105) screws.
NOTE: Tighten (105) screws to 35 - 40 in. lbs (4.0 - 4.5 Nm).
4. Install (140) valve insert and (141) valve plate into (135)
valve block. 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) gasket and (233) adapter plate to (135)
valve block.
NOTE: Assemble (233) adapter plate with notched side down.
6. Assemble (132 and 166) gaskets and (176) checks and to
(101)body.
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.
3. Install new (168) “O” rings and (169) seal - Note the lip direc-
tion. Lubricate and replace (167).
4. Reassemble remaining parts, replace (173 and 174) “O”rings.
7. Assemble (135) valve block and components to
(101) body, securingwith (134) screws. NOTE: Tight-
en (134) screws to 35 - 40 in. lbs (4.0 - 4.5 Nm).
Page 6 of 8
PD10E-X-X (en)
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PARTS LIST / PD10E-X-X AIR SECTION
173
118
169
168
PILOT VALVE
PART GROUP
172
171
170
174
121
167
173
118
121
174
166
140
141
233
107
105
133
135
Notch
134
43
200
132
176
101 181 103
201
Insert screwdriver here to remove (233) adapter plate.
111
137
138
139
136
107
236
MAJOR
VALVE
TORQUE REQUIREMENTS
NOTE: DO NOT OVERTIGHTEN FASTENERS.
ALL FASTENERS ARE METRIC.
Torque (105 and 134) screw to 35 - 40 in. lbs (4.0 - 4.5 Nm).
Figure 3
LUBRICATION / SEALANTS
Apply Lubriplate FML-2 grease to “O" rings, ”U" Cups & mating parts.
Apply anti-seize compound to threads at assembly.
A 637395-7 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, 166, 176 (2), 200, 233 and 236 (4)
PD10E-X-X (en)
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TROUBLE SHOOTING
Product discharged from exhaust outlet.
Low output volume, erratic flow, or no flow.
Check for diaphragm rupture.
Check air supply.
Check tightness of (6) diaphragm screw.
Check for plugged outlet hose.
Check for kinked (restrictive) outlet material hose.
Check for kinked (restrictive) or collapsed inlet
material hose.
Air bubbles in product discharge.
Check connections of suction plumbing.
Check“O” rings between intake manifold and inlet side
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-collaps-
ing type, capable of pulling a high vacuum.
Check all joints on the inlet manifolds and suction
connections. These must be air tight.
fluid caps.
Check tightness of (6) diaphragm screw.
Motor blows air or stalls.
Check (176) check valve for damage or wear.
Check for restrictions in valve / exhaust.
Inspect the pump for solid objects lodged in the dia-
phragm chamber or the seat area.
DIMENSIONAL DATA
(Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
14-1/8"(358.5 mm)
16-1/32"(407.0 mm)
8-5/16"(211.1 mm)
1" A.N.S.I. / DIN Flange
6-31/32"
(176.6 mm)
Outlet
16-1/32"
(407.0 mm)
13-25/32"
(349.8 mm)
Inlet
8-1/32"
(203.4 mm)
2-11/32"
(59.4 mm)
5-1/32"
(127.6 mm)
6-9/32"
1/2"(12.7 mm)
7/16"(11.1 mm)
4-1/16"
(103.0 mm)
10-1/16"(255.3 mm)
16-1/32"(407.3 mm)
(159.6 mm)
Figure 4
Air Inlet 1/4 - 18 N.P.T.
PN 97999-1159
PD10E-X-X (en)
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