OPERATOR’S MANUAL

INCLUDING: OPERATION, INSTALLATION & MAINTENANCE

PD30X-X-B

RELEASED: 8-14-98

REVISED:

(REV. J)

3-7-01

3” 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 Chart to match the pump material options.

637303ĆXX for Fluid Section Repair (see page 4). Note: This kit also contains several air motor seals which will need to be replaced.

637302 for Air Section Repair (see page 6).

3'' DIAPHRAGM PUMP

PD30XĆXXXĆXXXĆB

PUMP DATA

Models . . .

See Model Description Chart for ĆXXX".

Pump Type Metallic Air Operated Double Diaphragm

Material

Weight

. . .

. . . .

See Model Description Chart.

Aluminum (wet end)

Cast Iron (wet end)

Hastelloy (wet end)

. . . . . .

. . . . . .

. . . . . .

Stainless Steel (wet end) . .

113 lbs (51.3 kgs)

197 lbs (89.4 kgs)

203 lbs (92.1 kgs)

203 lbs (92.1 kgs)

(add 40 lbs [18.1 kg] for stainless steel air motor section)

Maximum Air Inlet Pressure

Maximum Outlet Pressure

. . . . . . . . .

Maximum Material Inlet Pressure

Maximum Flow Rate (flooded inlet)

. . . . .

. . . . . . . . . . .

. . . . . .

Displacement / Cycle @ 100 p.s.i.g.

Maximum Particle Size

Maximum Temperature Limits

Dimensional Data . . . . . . . . . . . . . . . . .

Mounting Dimensions . .

Noise Level @ 70 p.s.i., 50 c.p.m.

À

. . .

. . . . . . . . . . . . .

. . . . . . . .

10Ć5/32" x 12Ć1/16" (258 mm x 306 mm)

. . . .

120 p.s.i.g. (8.3 bar)

10 p.s.i.g. (.69 bar)

120 p.s.i.g. (8.3 bar)

275 g.p.m. (1041 l.p.m.)

2.8 gal. (10.6 lit.)

3/8" dia. (9.5 mm)

200 _ F (93 _ C) see page 8

83.0 db(A) Á

À Tested with 67263 muffler assembly installed.

Á The pump sound pressure levels published here have been updated to an Equivalent

Continuous Sound Level (L

Aeq

) to meet the intent of ANSI S1.13Ć1971, CAGIĆPNEUĆ

ROP S5.1 using four microphone locations.

NOTICE:All possible options are shown in the chart however certain comĆ binations may not be recommended, consult a representative or the factoĆ ry if you have questions concerning availability .

GENERAL DESCRIPTION

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 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 presĆ sure and will stop cycling once maximum line pressure is reached (disĆ pensing device closed) and will resume pumping as needed.

D005

MODEL DESCRIPTION CHART

PD30 X Ć X X X Ć X X X Ć B

CENTER SECTION MATERIAL

A - Aluminum S - Stainless Steel

THREAD

A - N.P.T.F.

B - BSP

FLUID CAPS & MANIFOLD MATERIAL

A - Aluminum

C - Cast Iron

H - Hastelloy

S - Stainless Steel

HARDWARE MATERIAL

P - Plated Steel S - Stainless Steel

SEAT MATERIAL

A - Santoprene R

G - Nitrile

L - Hastelloy

S - 316 Stainless Steel

K - PVDF (Kynar R ) H - Hard 440 Stainless Steel

BALL MATERIAL

A - Santoprene

G - Nitrile

T - Teflon

V - Viton

R

R

DIAPHRAGMMATERIAL

A - Santoprene

G - Nitrile

T - Teflon

V - Viton

FLUID SECTION SERVICE KIT SELECTION

EXAMPLE: MODEL # PD30AĆACSĆSAAĆB

FLUID SECTION SERVICE KIT # 637303ĆAA

PD30X Ć XXX Ć X X X Ć B

637303 Ć X X

BALL DIAPHRAGM

INGERSOLL-RAND COMPANY

P.O. BOX 151 D ONE ARO CENTER D BRYAN, OHIO 43506Ć0151

&

(419) 636-4242 D FAX (419) 633-1674 E

2001 D PRINTED IN U.S.A.

OPERATING AND SAFETY PRECAUTIONS

READ, UNDERSTAND, AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.

EXCESSIVE AIR PRESSURE

STATIC SPARK

HAZARDOUS MATERIALS

HAZARDOUS PRESSURE

WARNING EXCESSIVE AIR PRESSURE. Can cause personĆ al injury, pump damage or property damage.

S Do not exceed the maximum inlet air pressure as stated on the pump model plate.

S Be sure material hoses and other components are able to withĆ stand fluid pressures developed by this pump. Check all hoses for damage or wear. Be certain dispensing device is clean and in proper working condition.

WARNING STATIC SPARK. Can cause explosion resulting in severe injury or death. Ground pump and pumping system.

S Use the pump grounding screw terminal provided. Use Aro

Part No. 66885Ć1 Ground Kit or connect a suitable ground wire

(12 ga. min.) to a good earth ground source.

S Secure pump, connections and all contact points to avoid vibration and generation of contact or static spark.

S Consult local building codes and electrical codes for specific grounding requirements.

S After grounding, periodically verify continuity of electrical path to ground. Test with an ohmmeter from each component

(e.g., hoses, pump, clamps, container, spray gun, etc.) to ground to insure continuity. Ohmmeter should show 100 ohms or less.

S Submerse the outlet hose end, dispensing valve or device in the material being dispensed if possible. (Avoid free streamĆ ing of material being dispensed.)

S Use hoses incorporating a static wire.

S Use proper ventilation.

S Keep inflammables away from heat, open flames and sparks.

S Keep containers closed when not in use.

WARNING Pump exhaust may contain contaminants. Can cause severe injury. Pipe exhaust away from work area and personnel.

S In the event of a diaphragm rupture material can be forced out of the air exhaust muffler.

S Pipe the exhaust to a safe remote location when pumping hazĆ ardous or inflammable materials.

S Use a grounded 1" min. i.d. hose between the pump and the

S muffler.

WARNING

HAZARDOUS PRESSURE. Can result in serious injury or property damage. Do not service or clean pump, hoses or dispensing valve while the system is pressurized.

Disconnect air supply line and relieve pressure from the sysĆ tem by opening dispensing valve or device and / or carefully and slowly loosening and removing outlet hose or piping from pump.

WARNING HAZARDOUS MATERIALS. Can cause serious injury or property damage. Do not attempt to return a pump to the factory or service center that contains hazardous material.

Safe handling practices must comply with local and national laws and safety code requirements.

S Obtain Material Safety Data Sheets on all materials from the supplier for proper handling instructions.

WARNING EXPLOSION HAZARD. Models containing aluĆ minum wetted parts cannot be used with III.ĆTrichloroethane,

Methylene Chloride or other Halogenated Hydrocarbon solĆ vents which may react and explode.

S Check pump motor section, fluid caps, manifolds and all wetted parts to assure compatibility before using with solĆ vents of this type.

WARNING

MISAPPLICATION HAZARD. Do not use models containing aluminum wetted parts with food products for huĆ man consumption. Plated parts can contain trace amounts of lead.

CAUTION Verify the chemical compatibility of the pump wetted parts and the substance being pumped, flushed or reĆ circulated. Chemical compatibility may change with temperaĆ ture and concentration of the chemical(s) within the substances being pumped, flushed or circulated. For specific fluid compatibility, consult the chemical manufacturer.

CAUTION Maximum temperatures are based on mechaniĆ cal stress only. Certain chemicals will significantly reduce maximum safe operating temperature. Consult the chemical manufacturer for chemical compatibility and temperature limĆ its. Refer to PUMP DATA on page 1 of this manual.

CAUTION Be certain all operators of this equipment have been trained for safe working practices, understand it's limitaĆ tions, and wear safety goggles / equipment when required.

CAUTION

Do not use the pump for the structural support of the piping system. Be certain the system components are properly supported to prevent stress on the pump parts.

S Suction and discharge connections should be flexible conĆ nections (such as hose), not rigid piped, and should be comĆ patible with the substance being pumped.

CAUTION Prevent unnecessary damage to the pump. Do not allow pump to operate when out of material for long periĆ ods of time.

S Disconnect air line from pump when system sits idle for long periods of time.

CAUTION

Use only genuine ARO replacement parts to asĆ sure compatible pressure rating and longest service life.

WARNING

CAUTION

NOTICE

= Hazards or unsafe practices which could result in severe personal injury, death or substantial property damage.

= Hazards or unsafe practices which could result in minor personal injury, product or property damage.

= Important installation, operation or maintenance information.

PAGE 2 OF 8 PD30XĆXĆB

AIR AND LUBE REQUIREMENTS

S

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 lubrication required other than 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.

OPERATING INSTRUCTIONS

S 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 aperiod of time.

S Disconnect the air supply from the pump if it is to be inactive for a few hours.

S 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 collapse.

S When the diaphragm pump is used in a forcedĆfeed (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.

MAINTENANCE

Refer to the part views and descriptions as provided on page 4 through

7 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 SECĆ

TION is divided further to match typical part MATERIAL OPTIONS.

MAINTENANCE (CONT’D)

S Provide a clean work surface to protect sensitive internal moving parts from contamination from dirt and foreign matter during serĆ vice disassembly and reassembly.

S Keep good records of service activity and include pump in prevenĆ tive maintenance program.

S Before disassembling empty captured material in the outlet manĆ ifold by turning the pump upside down to drain material from the pump.

FLUID SECTION DISASSEMBLY

1. Remove top manifold(s).

2. Remove (22) balls, (19) O" rings and (21) seats.

3. Remove (15) fluid caps.

NOTE: Only Teflon diaphragm models use a primary (7) diaphragm and a backup (8) diaphragm. Refer to the auxiliary view in figure 1.

4. Remove the (6) diaphragm washer, (7) or (7 / 8) diaphragms, (5) backup washer and (196) cushion.

NOTE: Do not scratch or mar the surface of (1) diaphragm rod.

FLUID SECTION REASSEMBLY

SERVICE NOTE: ARO PN 204214ĆT Diaphragm Assembly Tool is recĆ ommended for use when reassembling the pump.

S Reassemble in reverse order.

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 Lubriplate R

FMLĆ2 Grease. (94276 grease packet is included in service kit.)

S Be certain the diaphragm assembly bottoms out on the (1) rod, back off Teflon Diaphragm assembly far enough to align holes.

S For models with Teflon diaphragms: Item (8) Santoprene diaĆ phragm is installed with the side marked AIR SIDE" towards the pump center body. Install the (7) Teflon Diaphragm with the side marked FLUID SIDE" towards the fluid cap.

S ReĆcheck torque settings after pump has been reĆstarted and run a while.

PD30XĆXĆB

Viton R and Teflon R are trademarks of the DuPont Company S Kynar R is a registered trademark of Penwalt Corp.

Santoprene R is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P.

S Lubriplate R is a registered trademark of Lubriplate Division (Fiske Brothers)

PAGE 3 OF 8

PARTS LIST / PD30X-X-B FLUID SECTION

FLUID SECTION SERVICE KITS (637303-XX)

L KITS INCLUDE: BALLS (See Ball Option, refer to ĆXX in chart below), DIAPHRAGMS (See Diaphragm Option, refer to ĆXX in chart below), and items; 3, 19, 70, 144, 175, 196, (listed below) plus (174) and 94276 Lubriplate FMLĆ2 grease (page 6).

SEAT OPTIONS PD30XĆXXXĆXXXĆB

21"

ĆXXX SEAT (4) [MTL] ĆXXX SEAT (4) [MTL]

ĆAXX 94104ĆA

ĆGXX 94104ĆG

ĆHXX 94114

[SP]

[B]

[SH]

ĆKXX 94621ĆK

ĆLXX 94939

ĆSXX 94113

[K]

[Ha]

[SS]

[A] = Aluminum

[B] = Nitrile

[C] = Carbon Steel

[Co] = Copper

[CI] = Cast Iron

[E] = E.P.R.

[Ha] = Hastelloy Ć C

MATERIAL CODE

[K] = PVDF

[SH] = Hard S'Steel

[SP] = Santoprene

[SS] = Stainless Steel

[T] = Teflon

[V] = Viton

ĆXXX

ĆXAX

ĆXGX

ĆXTX

ĆXVX

L

BALL OPTIONS PD30XĆXXXĆXXXĆB

22"

(3.25" dia.)

19"

BALL

94103ĆA

94103ĆG

94103ĆT

94103ĆV

QTY [MTL] GASKET QTY [MTL]

(4)

(4)

[SP] 94115

[B] Y325Ć350

(4)

(4)

[E]

[B]

(4)

(4)

[T]

[V]

Y328Ć350

Y327Ć350

(4)

(4)

[T]

[V]

DIAPHRAGM OPTIONS PD30XĆXXXĆXXXĆB

L

SERVICE KIT

L

7" / 8"

ĆXXX

ĆXX = (Ball)

ĆXX = (Diaphragm) DIAPHRAGM(2) [MTL]

ĆXXA

ĆXXG

637303ĆXA

637303ĆXG

94091ĆA

94091ĆG

[SP]

[B]

ĆXXT

ĆXXV

637303ĆXT

637303ĆXV

94090ĆT / 94110ĆA [T/SP]

95345 [V]

CENTER SECTION PART OPTIONS PD30XĆ

ITEM DESCRIPTION(Size in inches)

PD30AĆ

QTY PART NO.

PD30SĆ

[MTL] PART NO.

5 Backup Washer

68 Air Cap

69 Air Cap

(2) 94831Ć1

(1) 94030Ć1

(1) 94030Ć2

L

126 Pipe Plug (1/4 Ć 18 N.P.T. x 7/16") (2) ----n 175 O" Ring (3/32" x d 1" o.d. / f 1Ć1/16" o.d.) (2) Y325Ć117 d

[C] 94831Ć2

[A] 94031Ć1

[A] 94031Ć2

--Y17Ć51ĆS

[B] Y325Ć118 f

[MTL]

[SS]

[SS]

[SS]

[SS]

[B]

MANIFOLD THREAD / FLUID CAP MATERIAL OPTIONS PD30XĆXXXĆ

ITEM DESCRIPTION(Size in inches)

PD30XĆXAXĆ PD30XĆXCXĆ PD30XĆXHXĆ PD30XĆXSXĆ

QTY PART NO.

[MTL] PART NO.

[MTL] PART NO.

[MTL] PART NO.

[MTL]

6 Fluid Side Washer

9 Washer (3/16" i.d. x 2" o.d. x 5/32")

14 Cap Screw (3/4" Ć 16 x 3Ć1/4")

15 Fluid Cap

32 Leg (PD30AĆ)

Leg (PD30SĆ)

(2)

(2)

(2)

(2)

(2)

(2)

94802

Y13Ć12ĆT

Y5Ć134ĆT

94024

-----

-----

60 Outlet Manifold (1) 94700Ć[ u ]

61 Inlet Manifold (1) 94699Ć[ u ] u For N.P.T.F. thread models (PD30XĆAXXĆXXXĆB), use Ć1"

For BSP thread models (PD30XĆBXXĆXXXĆB), use Ć2".

[A] 94803

[SS] Y13Ć12ĆT

[SS] Y5Ć134ĆT

[A] 94106

--94701Ć1

--94701Ć2

[A] 94702Ć[ u ]

[A] 94305Ć[ u ]

[SS] 94947

[SS] 94949

[SS] 94948

[CI] 94693

[C] N / A

[SS] 94703Ć2

[CI] 94809Ć[ u ]

[CI] 94691Ć[ u ]

[Ha] 94803

[Ha] Y13Ć12ĆT

[Ha] Y5Ć134ĆT

[Ha] 94107

N / A 94703Ć1

[SS] 94703Ć2

[SS]

[SS]

[SS]

[SS]

[C]

[SS]

[Ha] 94704Ć[ u ] [SS]

[Ha] 94216Ć[ u ] [SS]

EXTERNAL HARDWARE OPTION PD30XĆXXXĆ

ITEM DESCRIPTION(Size in inches)

PD30XĆXXPĆ

QTY PART NO.

PD30XĆXXSĆ

[MTL] PART NO.

[MTL]

26 Screw (M12 x 1.75 Ć 6g x 45 mm)

27 Screw (M12 x 1.75 Ć 6g x 60 mm)

29 Nut (M12 x 1.75 Ć 6g)

(12) 94412Ć1

(16) 94991Ć1

(16) 95053Ć1

[C] 94412Ć2

[C] 94991

[C] 95053

[SS]

[SS]

[SS]

COMMON PARTS

ITEM DESCRIPTION(Size in inches) Qty PART NO.

[MTL] ITEM DESCRIPTION (Size in inches) Qty PART NO.

[MTL]

L

1 Rod

3 O" Ring (1/8" x 1" o.d.)

(1) 94984

(2) Y328Ć210

[C]

[T]

131 Screw (M10 x 1.5 - 6g x 120 mm)

Ln 144 U" Cup (3/16" x 1Ć3/8" o.d.)

(4) 94531

(2) Y186Ć51

[C]

[B]

43 Ground Lug (1) 93004 [Co] n 180 Gasket (.406" i.d. x .031" thick)

L n 70 Gasket (2) 94100 [B] L 196 Cushion

V Smart Parts" keep these items on hand in addition to the Service Kits for fast repair and reduction of down time.

(4) 94098

(2) 94631

[Co]

[SP]

PAGE 4 OF 8 PD30XĆXĆB

68

PARTS LIST / PD30X-X-B FLUID SECTION

FOR THE

AIR MOTOR SECTION

SEE PAGES 6 & 7

MATERIAL

COLOR CODE

DIAPHRAGM BALL

COLOR

60

NITRILE

PVDF

BLACK

N/A

SANTOPRENE TAN

SANTOPRENE GREEN

(BACKUP)

TEFLON

VITON

WHITE

RED (

N/A

TAN

N/A

S

WHITE

)

YELLOW (Ć) YELLOW ( S )

26 , G

(Ć) STRIPE ( S ) DOT

5

7

3 1

2 4

Torque Sequence

22

21

19

= k

1 69

70 k

144 k 70 k 5 196 7 3 k 6 15

8

6

126 144 k 43 175 k

29

22

19

= k

21

180 131 x

9 14 , g

27 , G

61

26 , G

32

FIGURE 1

.

TORQUE REQUIREMENTS ,

NOTE: DO NOT OVERTIGHTEN FASTENERS

ALL FASTENERS ARE METRIC

(14) Cap Screw 60 Ć 70 ft lbs (81.4 Ć 94.9 Nm)

(26 and 27) Fluid Caps / Manifold Screw 60 Ć 70 ft lbs (81.4 Ć 94.9 Nm), g Apply Loctite 204 to threads.

G Apply antiĆseize compound to threads when using

SS fasteners and stainless steel wet ends.

LUBRICATION / SEALANTS k Apply Lubriplate FMLĆ2 Grease to all

=

O" rings, U" Cups & mating parts.

USED WITH ĆHXX, ĆKXX, ĆLXX & ĆSXX ONLY x Apply Loctite 242 to threads at assembly.

D006

PD30XĆXĆB

Z Lubriplate FMLĆ2 is a white food grade petroleum grease. MSDS available upon request.

VIEW OF TWO PIECE TEFLON DIAPHRAGM

SANTOPRENE

8 7

TEFLON

PAGE 5 OF 8

PARTS LIST / PD30X-X-B AIR SECTION

n Indicates parts included in 637302 Air Section Service Kit shown below and items (70), (144), (175) and (180) shown on page 4.

ITEM DESCRIPTION (Size in inches) QTY PART NO.

AIR MOTOR PARTS

[MTL]

101 Center Body (PD30AĆ )

Center Body (PD30SĆ )

103 Bushing

107 Inlet Plug

(1) 94028

(1) 94109

(1) 94092

(1) 94034

109 Piston (1) 92011 n 110 U" Cup (1Ć3/8" o.d.) (Also Item #144) (1) Y186Ć51

111 Spool (PD30AĆ )

Spool (PD30SĆ )

112 Washer (1.556" o.d.) n 113 O" Ring (small) (1/8" x 1Ć1/4" o.d.)

(1) 92005

(1) 93047

(5) 92877

(5) Y325Ć214 n 114 O" Ring (large) (3/32" x 1Ć9/16" o.d.) (7) Y325Ć126

V 115 Spacer (4) 92876

116 Spacer

118 Actuator Pin (.250" x 2.276")

(1) 94027

(2) 94083

121 Sleeve

~ 127 90 _ St. Elbow (1Ć1/2 Ć 11Ć1/2 N.P.T.) n 132 Gasket

133 Lockwasher

Lockwasher (1/4") (PD30SĆ )

134 Screw (M6 x 1.0 x 16 mm) (PD30AĆ )

Screw

(Valve Body)

(1/4") (PD30AĆ )

(M6 x 1.0 x 16 mm) (PD30SĆ )

135 Valve Block (PD30AĆ )

(2) 94084

(1) 94860

(1) 94099 [B]

(3) Y117Ć416ĆC [C]

(3) Y14Ć416ĆT

(4) 96721030

(4) 96720081

(1) 94032

[B]

[Z]

[A]

[SS]

[D]

[C / I]

[SS]

[C]

[SS]

[A]

[A]

[C]

[Z]

[B]

[A]

[SS]

[D]

[C]

[D]

[B]

ITEM DESCRIPTION (Size in inches) QTY PART NO.

[MTL]

Valve Block (PD30SĆ )

136 Piston Plug

(1) 94318

(1) 94033 n 146 O" Ring z (3/32" x 1Ć1/16" o.d.) (1) Y325Ć118 n 147 O" Ring z (1/8" x 1/2" o.d.) Also #174 (2) Y325Ć202 n 166 Track Gasket D n 167 Pilot Piston (includes 168 and 169)

(1) 94026

(1) 67164

168 O" Ring (3/32" x 5/8" o.d.)

169 U" Cup (1/8" x 7/8" o.d.)

170 Piston Sleeve n 171 O" Ring (3/32" x 1Ć1/8" o.d.)

(2) 94433

(1) Y240Ć9

(1) 94081

(1) Y325Ć119 n n

Ln

172 O" Ring

173 O" Ring

(1/16" x 1Ć1/8" o.d.)

(1/16" x 1Ć3/8" o.d.)

174 O" Ring (1/8" x 1/2" o.d.)

(1) Y325Ć22

(2) Y325Ć26

(2) Y325Ć202

(2) 94102 n 176 Diaphragm (Check Valve) n 177 Retaining Ring

181 Roll Pin z

(1.804" dia.)

(.156 o.d. x 3/4" long)

(1) Y147Ć16ĆC [C]

(4) Y178Ć56ĆS [SS]

~ 201 Muffler

L Ă n Lubriplate FMLĆ2 Grease

Lubriplate Grease Packets (10)

(1) 94810

(1) 94276 z Used on Stainless Steel models (PD30SĆ ) only.

637308

[B]

[B]

[B]

[SP]

D Used on Aluminum models (PD30AĆ ) only.

~ Items not shown.

[U]

[B]

[Br]

[B]

[SS]

[D]

[B]

[B]

[B]

[D]

AIR MOTOR SECTION SERVICE

Service is divided into two parts - 1.Pilot Valve, 2.Major Valve.

GENERALREASSEMBLY NOTES:

S Air Motor Section Service is continued from Fluid Section repair.

S Inspect and replace old parts with new parts as necessary. Look for

S

S

S

S deep scratches on metallic surfaces, and nicks or cuts in O" rings.

Take precautions to prevent cutting O" rings upon installation.

Lubricate O" rings with Lubriplate FMLĆ2 Grease.

Do not overĆtighten fasteners, refer to torque specification block on view.

ReĆtorque fasteners following restart.

SERVICE TOOLS - To aid in the installation of (168) O" rings onto the (167) pilot piston, use Tool # 204130ĆT, available from Aro.

[A] = Aluminum

[B] = Nitrile

[Br] = Brass

[C] = Carbon Steel

MATERIAL CODE

[D] = Acetal

[I] = Iron

[SP] = Stantoprene

[SS] = Stainless Steel

[U] = Polyurethane

[Z] = Zinc

MAJOR VALVE DISASSEMBLY

1. Remove (135) valve block, exposing gaskets (166 and 132) and

(176) checks.

2. Remove (177) snap ring and (107) inlet plug.

3. On the side opposite the air inlet, push on the inner diameter of

(111) spool. This will force the (136) piston plug and (109) piston out. Continue pushing the (111) spool and remove. Check for scratches or gouges.

4. Remove the Major Valve parts (112 Ć 116).

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 and 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 direction.

Lubricate and replace (167).

4. Reassemble remaining parts, replace (173 and 174) O" rings.

MAJOR VALVE REASSEMBLY

1. Replace (112) washer, (114) O" ring and (113) O" ring onto (115) spacer and insert etc. Continue this routine to build the major valve stack.

NOTE: Be careful to orient spacer legs away from blocking interĆ nal ports.

2. Replace (111) spool on (136) plug, (110) seal on (109) piston and replace (109), (136) plug and (177) snap ring.

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 PD30XĆXĆB

PARTS LIST / PD30X-X-B AIR SECTION

MAJOR VALVE CROSS SECTION DETAIL

109 110 k 112 114 k 113 k 115 111 116 174 k

118

121

169 k

168 k

172 k

171 k

PILOT VALVE

PART GROUP

173 k

121

118

174 k

FIGURE 3

173 k

167

170

177

136

109

114 k

110 k u Substitute these

O" rings for 166" on models PD30S.

147 k

146 k

111

176

166 u k

132 k

135

.

134

133

103

101

FIGURE 2

181

(PD30SĆ only) 112

113 k

114 k

115

Optional 94117 Muffler

MAJOR VALVE

See cross section detail figure 3 above.

113 k

114 k

116

114 k

107

A Major Valve Service Asm. is available separately, which includes the following:

Valve Assembly Pump Models Items Included

67089Ć1

67089Ć2

PD30AĆ

PD30SĆ

107 Ć 116, 132, 135, 136, 166, 176, 177

107 Ć 116, 132, 135, 136, 146, 147, 176, 177

PD30XĆXĆB

IMPORTANT

BE CERTAIN TO ORIENT (115) SPACER LEGS

AWAY FROM BLOCKING INTERNAL PORTS

WHEN REASSEMBLING AIR SECTION.

.

TORQUE REQUIREMENTS

,

NOTE: DO NOT OVERTIGHTEN FASTENERS

ALL FASTENERS ARE METRIC

Torque (134) Screw to 40 Ć 50 in. lbs (4.5 Ć 5.6 Nm).

LUBRICATION / SEALANTS k Apply Lubriplate FMLĆ2 Grease to O" rings, U" Cups

& mating parts.

PAGE 7 OF 8

TROUBLE SHOOTING

S

S

S

S

Check for diaphragm rupture.

Check tightness of (14) cap screw.

Air bubbles in product discharge.

S Check connections of suction plumbing.

S Check O" rings between intake manifold and fluid caps.

Check tightness of (14) cap screw.

Check (176) check valve for damage or wear.

Check for restrictions in valve / exhaust.

S Check air supply.

S Check for plugged outlet hose.

Check for kinked (restrictive) outlet material hose.

S Check for kinked (restrictive) or collapsed inlet material hose.

S Check for pump cavitation Ć 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 nonĆcolĆ lapsing type, capable of pulling a high vacuum.

S Check all joints on the inlet manifolds and suction connections.

These must be air tight.

S Inspect the pump for solid objects logged in the diaphragm chamĆ ber or the seat area.

DIMENSIONAL DATA

(Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).

17Ć11/16" (449.2 mm)

15" (381 mm)

2Ć3/4"

(69.9 mm)

(PD30XĆAXXĆXXXĆB)

(PD30XĆBXXĆXXXĆB)

3 Ć 8 N.P.T.F. Ć 1

Rp 3 ( 3 Ć 11 BSP parallel)

A"

OUTLET

30"

(761.7 mm)

32"

(812.5 mm)

D009

PAGE 8 OF 8

Air Inlet

3/4 Ć 14 N.P.T.F. Ć 1

Dotted lines show optional

67263 Muffler Assembly.

10Ć5/32" (258 mm)

C"

23Ć3/32" (586.3 mm)

PD30XĆXAX

PD30XĆXCX

PD30XĆXHX

PD30XĆXSX

A"

23Ć5/8" (598.7 mm)

23Ć5/8" (598.7 mm)

23Ć1/8" (587.3 mm)

23Ć1/8" (587.3 mm)

B"

INLET

9/16" Slot (14.3 mm)

12Ć1/16" (306.5 mm)

OPTIONAL ACCESSORY: 66109 Airline Connection Kit

B"

2Ć3/8" (60.3 mm)

2Ć7/16" (61.1 mm)

2Ć3/4" (69.9 mm)

2Ć3/4" (69.9 mm)

C"

11" (279.4 mm)

11Ć11/16" (296.1 mm)

11Ć11/16" (296.1 mm)

11Ć11/16" (296.1 mm)

FIGURE 4

Exhaust Port

1Ć1/2 Ć 11Ć1/2 N.P.T.

PN 97999Ć813

PD30XĆXĆB