OPERATOR’S MANUAL
PD05X-XXX-XXX-B
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
PE05X-XXX-XXX-B
RELEASED:
REVISED:
(REV. 07)
8-27-08
5-28-10
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 material op-
tions.
637427-XX for fluid section repair (see page 4).
637428 for air section repair (see pages 6 and 8).
PUMP DATA
Models. . . . . . . . . . . . . . . . . see Model Description Chart for “-XXX”
Pump Type. . . . . . . . . . . . . Metallic Air Operated Double Diaphragm
Material. . . . . . . . . . . . . . . . see Model Description Chart
Weight . . PX05A-XAS-XXX-B . . . . . . . . . . . . 10.36 lbs (4.70 kgs)
PX05A-XSS-XXX-B . . . . . . . . . . . . 16.57 lbs (7.52 kgs)
PX05R-XAS-XXX-B . . . . . . . . . . . . 8.04 lbs (3.65 kgs)
PD05R-XXX-XXX-B
PD05A-XXX-XXX-B
Figure 1
PX05R-XSS-XXX-B . . . . . . . . . . . . 14.25 lbs (6.46 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)
Maximum Outlet Pressure . . . . . . . . . . . . . 100 p.s.i.g. (6.9 bar)
Air Consumption @ 40 p.s.i.. . . . . . . . . . . . . 1 c.f.m. / gallon (approx.)
Maximum Flow Rate (flooded inlet) . . . 12.0 g.p.m. (45.4 l.p.m.)
Displacement / Cycle @ 100 p.s.i.g. . . . . 0.039 gal. (0.15 lit.)
Maximum Particle Size . . . . . . . . . . . . . . . . 3/32”dia. (2.4 mm)
Maximum Temperature Limits (diaphragm / ball / seat material)
E.P.R. / EPDM . . . . . . . . . . . . . . . . . . . -60° to 280° F (-51° to 138° C)
Hytrel® . . . . . . . . . . . . . . . . . . . . . . . . . -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)
Polyurethane. . . . . . . . . . . . . . . . . . . 10° to 150° F (-12° to 66° 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 pages 11 and 12
MODEL DESCRIPTION CHART
P X 05 X - X X S - X X X - B
Electronic Interface
D - None
E
-
Available
Center Section Material
A - Aluminum
R - Polypropylene
Fluid Connection
A - 1/2 - 14 N.P.T.F. - 1
B - Rp 1/2 (1/2 - 14 BSP parallel)
Fluid Cap & Manifold Material
A - Aluminum
Noise Level @ 70 p.s.i., 60 c.p.m.. . . . . . . . . 75.0 db(A)
c
S
-
Stainless steel
Hardware Material
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
S
-
Seat Material
Aluminum
P - Polypropylene
316 Stainless steel
F
-
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.
S
-
Ball Material
A - Santoprene
C - Hytrel
T
- PTFE
U - Polyurethane
V - Viton
G - Nitrile
S
-
Stainless steel
Diaphragm Material
A - Santoprene
C - Hytrel
T
-
PTFE / Santoprene
U - Polyurethane
V - Viton
G - Nitrile
Fluid Section Service Kit Selection
PD05X - XXX - X X X - B
637427 - X X
Example: Model #PD05A-AAS-SAA-B
Fluid Section Service Kit # 637427-AA
Ball
Diaphragm
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET – BRYAN, OHIO 43506
© 2010
CCN 15250384
(800) 495-0276 FAX(800) 892-6276
GENERAL DESCRIPTION
MAINTENANCE
The ARO diaphragm pump offers high volume delivery even at low
air pressure and a broad range of material compatibility 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 differen-
tial 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.
Pump cycling will begin as air pressure is applied and will continue
to pump and keep up with the demand. It will build and maintain
line pressure and will stop cycling once maximum line pressure is
reached (dispensing device closed) and will resume pumping as
needed.
Certain ARO “Smart Parts” are indicated which should be avail-
able for fast repair and reduction of down time.
Provide a clean work surface to protect sensitive internal mov-
ing parts from contamination from dirt and foreign matter dur-
ing 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 diaphragm
pump functions: 1. AIR SECTION, 2. FLUID SECTION. The Fluid
Section is divided further to match typical part Material Op-
tions.
Before disassembling, emptycaptured material in the outlet
manifold by turning the pump upside down to drain material
from the pump.
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AIR AND LUBE REQUIREMENTS
DIAPHRAGM PUMP SERVICE
EXCESSIVE AIR PRESSURE. Can cause pump dam-
WARNING
age, personal injury or property damage.
GENERAL SERVICE NOTES:
A filter capable of filtering out particles larger than 50 microns
should be used on the air supply. There is no lubrication re-
quired 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.
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Inspect and replace old parts with new parts as necessary. Look
for deep scratches on metallic surfaces, and nicks or cuts in “O”
rings.
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Tools needed to complete disassembly and repair:
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7/8” wrench, 1/2” socket or wrench, 3/8” socket or wrench,
3/8” Allen wrench, 10 mm Allen wrench, T-10 Torx screw-
driver, torque wrench (measuring inch pounds), “O” ring
pick.
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OPERATING INSTRUCTIONS
Always flush the pump with a solvent compatible with the ma-
terial 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.
The outlet material volume is governed not only by the air sup-
ply, 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.
When the diaphragm pump is used in a forced-feed (flooded
inlet) situation, it is recommended that a “check valve” be in-
stalled at the air inlet.
Secure the diaphragm pump legs to a suitable surface to insure
against damage by vibration.
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FLUID SECTION DISASSEMBLY
1. Remove (61) top manifold.
2. Remove (19) “O” rings, (21) seats, (12) washers (where appli-
cable) and (22) balls.
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3. Remove (60) bottom manifold.
4. Remove (19) “O” rings, (21) seats, (12) washers (where appli-
cable) and (22) balls.
5. Remove (15) fluid caps.
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.
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FLUID SECTION REASSEMBLY
Reassemble in reverse order.
Lubricate (1) connecting rod with Lubriplate® or equivalent “O”
ring lubricant.
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Connecting rod (1) should be installed using 96571 bullet, in-
cluded in service kit.
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Install (5) washers with i.d. chamfer toward diaphragm.
When replacing PTFE diaphragms, install the 93465 Santo-
prene diaphragm behind the PTFE diaphragm.
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Hytrel® and Viton® are registered trademarks of the DuPont Company Kynar® is a registered trademark of Arkema Inc. ARO® is a registered trademark of Ingersoll-Rand Company
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Santoprene® is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. Loctite® and 242® are registered trademarks of Henkel Loctite Corporation
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572™ is a trademark of Henkel Loctite Corporation Lubriplate® is a registered trademark of Lubriplate Division (Fiske Brothers Refining Company)
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PD05X-XXX-XXX-B (en)
Page 3 of 12
PARTS LIST / PX05X-XXX-XXX-B FLUID SECTION
637427-XX Fluid section service kit includes: Balls (see Ball Option, refer to -XX in chart below), Diaphragms (see Diaphragm Option, refer to -XX in chart
below) and item 19 (listed below) plus items 144, 174 and 94276 Lubriplate FML-2 grease (pages 6 and 8).
n
SEAT OPTIONS
PX05X-XXX-XXX-B
BALL OPTIONS
PX05X-XXX-XXX-B
(3/4” diameter)
“22”
“21”
n
-XXX Seat
-FXX 95727
Qty Mtl
-XXX Ball
Qty Mtl
(4) [Sp]
-XXX Ball
Qty Mtl
(4)
(4)
[A]
[P]
-XAX 93100-E
-XCX 93100-C
-XGX 93100-2
-XSX 93410-1
-XTX 93100-4
-XUX 93100-8
-XVX 93100-3
(4)
(4)
(4)
[T]
[U]
[V]
-PXX 93098-10
-SXX 93409-1
(4)
(4)
[H]
[B]
(4) [SS]
(4) [SS]
MATERIAL CODE
DIAPHRAGM OPTIONS PX05X-XXX-XXX-B
[A] = Aluminum
[B] = Nitrile
[C] = Carbon Steel
[E] = E.P.R.
[GFN] = Glass filled Nylon
[H] = Hytrel
[K] = Kynar PVDF
[P] = Polypropylene
[Sp] = Santoprene
[SS] = Stainless Steel
[T] = PTFE
(3/32” x 1-5/16” o.d.)
“19”
Service Kit
“7”
“8”
n
n
n
n
-XX = (Ball)
-XXX -XX = (Diaphragm)
-XXA 637427-XA
-XXC 637427-XC
-XXG 637427-XG
-XXT 637427-XT
-XXU 637427-XU
-XXV 637427-XV
Diaphragm
Qty
Mtl Diaphragm
Qty
Mtl “O” Ring
- - - 93763
Qty
(4)
(4)
(4)
(4)
(4)
(4)
Mtl
[E]
93465
(2)
(2)
(2)
(2)
(2)
(2)
[Sp] - - - - -
[H] - - - - -
[B] - - - - -
[T] 93465
[U] - - - - -
[V] - - - - -
- - -
- - -
- - -
(2)
93465-9
93465-G
93111
- - - Y325-122
- - - Y325-122
[Sp] 93265
[B]
[B]
[T]
[U]
[V]
[U] = Polyurethane
[V] = Viton
93112
- - -
- - -
- - - 93119
93581-3
- - - Y327-122
MANIFOLD / FLUID CAP MATERIAL OPTIONS PX05X-XXX-XXX-B
Aluminum
Stainless Steel
PX05X-AAS-XXX-B PX05X-BAS-XXX-B PX05X-ASS-XXX-B PX05X-BSS-XXX-B
N.P.T. BSP N.P.T. BSP
Qty Part No. Mtl Part No. Mtl Part No. Mtl Part No.
(size)
Item Description
Mtl
- - -
12 Washer
(2) 95092
(2) 95064
(1) 95065
(1) 95066
(1) Y17-13-S
(1) - - - - -
[A] 95092
[A] 95064
[A] 95065-2
[A] 95066-2
[A] - - - - -
[A] 94624
[A] 94626
[A] 94625
- - - Y17-13-S
[K] - - - - -
- - - - - - - -
15 Fluid Cap
[SS] 94624
[SS] 94626-2
[SS] 94625-2
[SS]
[SS]
[SS]
- - -
60 Inlet Manifold
61 Outlet Manifold
(1/2 - 14 N.P.T. x 9/16”)
Pipe Plug
[K]
- - - - -
[K]
- - - - -
63
(R 1/2 [1/2 - 14 BSP taper])
- - - 96764691
- - - 96764691
[K]
COMMON PARTS
(size)
(size)
Item Description
Qty Part No.
(1) 96379
(2) 94645
(2) 94622
(2) 94628
(8) 94628
Mtl
[SS]
Item Description
Qty Part No.
(16) 93886
(1) 92956-1
Mtl
[SS]
[SS]
(5/16” - 18)
1
5
6
Connecting Rod
29 Hex Flange Nut
o
(models PX05R-XXX-XXX-B
only)(see page 9)
Diaphragm Washer
Diaphragm Washer
[GFN]
[SS]
43 Ground Strap
o
(5/16” - 18 x 3/4”)
(not shown)
14 Flange Bolt
26 Flange Bolt
[SS]
57 Ground Kit Assembly
(1) 66885-1
(1) Y227-2-L
- - -
[C]
(5/16” - 18 x 3/4”)
(1/8 - 27 N.P.T. x 1/4”)(models
PE05X-XXX-XXX-B only)(see pages 7 and 9)
[SS]
76 Pipe Plug
(5/16”- 18 x 1-1/4”) (PX05A-XXX-XXX-B)
Bolt
(16) Y84-502-T [SS]
(16) 93095 [SS]
27
(PX05R-XXX-XXX-B)
“Smart Parts“, keep these items on hand in addition to the service kits for fast
repair and reduction of down time.
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Page 4 of 12
PD05X-XXX-XXX-B (en)
PARTS LIST / PX05X-XXX-XXX-B FLUID SECTION
COLOR CODE
3
2
1
4
Diaphragm
Color
Ball
Material
Color
Hytrel
Nitrile
Cream
Black
Polyurethane Clear
Black (•)
Red (•)
Red
5
7
8
6
Santoprene
PTFE
Tan
White
Yellow (•) Yellow (•)
Tan
White
Viton
(•) Dot
(PX05X-XAS-XXX-B)
61
26
61
e
Torque Sequence
(
(PX05X-XSS-XXX-B)
FOR THE AIR MO-
TOR SECTION, SEE
PAGES 6 THRU 9.
e
c
f
27
1
5
7
6
14
(
22
12
21
19
c
e
29
15
(
22
12
21
19
e
26
60
63
(
(PX05X-XSS-XXX-B)
d
c
(PX05X-XAS-XXX-B)
60
63
Figure 2
d
View for PX05X-XXS-XXT-B (PTFE diaphragm)
configuration only.
ASSEMBLY TORQUE REQUIREMENTS
)
(
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(14) bolt, 95 - 105 in. lbs (10.7 - 11.9 Nm).
(26) bolt and (29) nut, 50 - 60 in. lbs (5.6 - 6.8 Nm), alternately and evenly,
then re-torque after initial run-in.
LUBRICATION / SEALANTS
Apply Lubriplate FML-2 grease to all “O” rings, “U” cups and mating parts.
Apply pipe sealant to threads.
c
d
e
Air side Santoprene (tan)
8
Apply anti-seize compound to threads and bolt and nut flange heads
which contact pump case when using stainless steel fasteners.
Apply Loctite® 242® to threads.
f
Fluid side PTFE (white)
7
Note: Lubriplate FML-2 is a white food grade petroleum grease.
PD05X-XXX-XXX-B (en)
Page 5 of 12
PARTS LIST / PX05A-XXX-XXX-B AIR MOTOR SECTION
Indicates parts included in 637428 air section service kit.
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AIR MOTOR PARTS LIST
(size)
(size)
Item
Description
Qty Part No.
(1) 95978
(1) 96091
(1) 96351
(1) 95919
(2) 97111
(2) 96092
(8) 96093
(1) 95979
(1) 96632
(1) 96214-1
(4) 94871
(1) 95980
(1) 95982
(1) 96464
(2) Y325-29
(1) 94395
(1) 96383
Mtl
[A]
[D]
[D]
[D]
[SS]
[D]
[SS]
[A]
[B]
Item
Description
Qty Part No.
(1) 93276
(1) 96173
(2) Y187-48
(1) 67382
(2) 96459
(1) 96384
(1) 96090
(2) Y325-17
(2) Y325-115
(2) Y325-105
(1) 96364
(1) 93110
(4) Y325-10
Mtl
(Ck)
(Ck)
[B]
[D]
[U]
[U]
[D]
[B]
[B]
[B]
[B]
[C]
101 Center Body
140 Valve Insert
141 Valve Plate
(right side)
103R Cover
103L Cover
(left side)
(3/16” x 1” o.d.)
144 “U” Cup Packing
np
p
(includes 168 and 169)
167 Pilot Piston
111 Major Valve Spool
118 Actuator Pin
121 Washer
(1/16” x 7/16” o.d.)
168 "O” Ring
(1/8” x 5/8” o.d.)
169 “U” Cup Packing
170 Spool Bushing
p
p
(#4 - 20 x 1/2”)
123 Screw
(1/16” x 13/16” o.d.)
129 Exhaust Cover
130 Gasket
171 “O” Ring
173 “O” Ring
174 “O” Ring
p
p
(3/32” x 7/8” o.d.)
(3/32” x 11/32” o.d.)
132 Air Manifold Gasket
[B]
np
p
(1/4” - 20 x 5-3/4”)
134 Flange Bolt
135 Valve Block
[SS]
[Z]
200 Porting Gasket
201 Muffler
(PD05A-XXX-XXX-B)
(PE05A-XXX-XXX-B)
(1/16” x 3/8” o.d.)
Plug, Large
[A]
[A]
[B]
232 “O” Ring
[B]
136
p
(1/4” - 14 x 1/2” o.d.)
250 Screw
(1) Y334-104-C [C]
(1/16” x 1-5/8” o.d.)
137 “O” Ring
p
p
p
(1/8” x 1” o.d.)
138 “U” Cup Packing
139 “U” Cup Packing
[U]
[U]
Lubriplate FML-2 grease
(1) 94276
637308
n p
(1/8” x 1-7/16” o.d.)
Lubriplate Grease Packets (10)
Indicates parts included in fluid section service kit, see page 4.
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MATERIAL CODE
MAJOR VALVE DISASSEMBLY
[A] = Aluminum
[B] = Nitrile
[C] = Carbon Steel
[Ck] = Ceramic
[D] = Acetal
1. Unthread (134) bolts, releasing (129) exhaust cover.
2. Pull (135) valve block and components from (101) center body.
3. Remove (132) gasket, (141) valve plate and (140) valve insert
from (135) valve block.
[SS] = Stainless Steel
[U] = Polyurethane
[Z] = Zinc
AIR MOTOR SECTION SERVICE
4. Remove (134) bolts, releasing (136) plug and (111) spool.
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.
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MAJOR VALVE REASSEMBLY
Air Motor Section service is continued from Fluid Section repair.
1. Assemble new (139 and 138) “U” cups on (111) spool - LIPS
MUST FACE EACH OTHER.
PILOT VALVE DISASSEMBLY
2. Assemble (137) “O”rings to (136) large plug.
3. Insert (111) spool into (136) large plug, then insert (136) large
plug into (135) valve block, being sure the (111) spool is rotated
to accept (140) valve insert.
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 iden-
tification dot toward (132) gasket.
5. Assemble (132 and 200) gaskets, (135) valve block, (130) gasket
and (129) exhaust cover to (101) center body, securing with
(134) bolts. NOTE: Tighten (134) bolts to 15 - 20 in. lbs (1.7 - 2.3
Nm).
1. Remove (123) screws, releasing (103) covers, (121) washers,
(118) actuator pins and (167) pilot piston.
2. Remove (170) spool bushing and inspect inner bore of bushing
for damage.
PILOT VALVE REASSEMBLY
1. Clean and lubricate parts not being replaced from service kit.
2. Assemble (171) “O” rings to (170) bushing and assemble bush-
ing into (101) center body.
3. Lubricate and assemble (167) pilot piston assembly into (170)
bushing.
4. Assemble (173 and 174) “O” rings and (121) washers to (103)
covers, then insert (118) actuator pins through assembly.
5. Assemble (144) “U” cups (note the lip direction) and (103) cov-
ers to (101) center body, securing with (123) screws. NOTE:
tighten (123) screws to 10 - 12 in. lbs (1.13 - 1.36 Nm).
Page 6 of 12
PD05X-XXX-XXX-B (en)
PARTS LIST / PX05A-XXX-XXX-B AIR MOTOR SECTION
PILOT VALVE PARTS
c
c
c
c
144 118 169
168
171
123
)
103L
c
173
c
232
130
129
201
c
174 121 167 170
140
132
c
144
135
134
138
103R
123
)
(
c
c
c
c
c
141
200
250 101
118 121 174
173
c
c
139
137
111
136
PILOT VALVE PARTS
g
76
Figure 3
MAJOR VALVE
ASSEMBLY TORQUE REQUIREMENTS
)
(
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(123) screw, 10 - 12 in. lbs (1.13 - 1.36 Nm).
(134) bolt, 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).
LUBRICATION / SEALANTS
Apply Lubriplate FML-2 grease to all “O” rings, “U” cups and mat-
ing parts.
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g
Apply Loctite® 572™ to threads.
PD05X-XXX-XXX-B (en)
Page 7 of 12
PARTS LIST / PX05R-XXX-XXX-B AIR MOTOR SECTION
Indicates parts included in 637428 air section service kit.
p
AIR MOTOR PARTS LIST
(size)
(size)
Item
Description
Qty Part No.
(1) 96315
(1) 96091
(1) 96351
(1) 96353
(1) 95919
(2) 97111
(2) 96092
(8) 96093
(1) 67367
(1) 67366
(1) 93107
(1) 96214-1
(4) 94871
(1) 96204
(1) 96352
(1) 96462
(3) Y325-29
(1) 94395
(1) 96383
Mtl
[PPG]
[D]
Item
Description
Qty Part No.
(1) 93276
Mtl
(Ck)
(Ck)
[B]
[B]
[D]
[U]
[U]
[D]
[B]
[B]
[B]
[B]
[C]
101 Center Body
140 Valve Insert
141 Valve Plate
(right side)
103R Cover
103L Cover
(1) 96173
(left side)
(3/16” x 1” o.d.)
[D]
144 “U” Cup Packing
(2) Y187-48
(1) Y325-24
(1) 67382
np
p
(1/16” x 1-1/4” o.d.)
107 Plug, Small
111 Major Valve Spool
118 Actuator Pin
121 Washer
[D]
166 “O” Ring
(includes 168 and 169)
[D]
167 Pilot Piston
p
(1/16” x 7/16” o.d.)
[SS]
[D]
168 "O” Ring
(2) 96459
(1/8” x 5/8” o.d.)
169 “U” Cup Packing
170 Spool Bushing
(1) 96384
p
(#4 - 20 x 1/2”)
123 Screw
[SS]
[PPG]
[PPG]
[Sy]
[B]
(1) 96090
(1/16” x 13/16” o.d.)
129 Muffler Assembly
171 “O” Ring
173 “O” Ring
174 “O” Ring
(2) Y325-17
(2) Y325-115
(2) Y325-105
(1) 96364
p
p
(optional)
(3/32” x 7/8” o.d.)
(3/32” x 11/32” o.d.)
129 Exhaust Cover
q
q
p
(optional)
130 Gasket
np
p
132 Air Manifold Gasket
200 Porting Gasket
(1/4” - 20 x 5-3/4”)
(optional)
134 Flange Bolt
135 Valve Block
[SS]
[PPG]
[D]
201 Muffler
(1) 93110
(1/16” x 3/8” o.d.) (optional)
232 “O” Ring
(4) Y325-10
(1) 637438
[B]
- - -
q
(PD05R-XXX-XXX-B)
(PE05R-XXX-XXX-B)
(includes items
Ported Exhaust Kit
Plug, Large
136
q
129, 130 and 232) (optional)
[D]
(1/16” x 1-5/8” o.d.)
137 “O” Ring
[B]
p
p
p
(1/8” x 1” o.d.)
138 “U” Cup Packing
139 “U” Cup Packing
[U]
Lubriplate FML-2 grease
(1) 94276
637308
n p
(1/8” x 1-7/16” o.d.)
[U]
Lubriplate Grease Packets (10)
Indicates parts included in fluid section service kit, see page 4.
n
MATERIAL CODE
MAJOR VALVE DISASSEMBLY
[B] = Nitrile
[PPG] = Glass filled Polypropylene
[SS] = Stainless Steel
[Sy] = Syn-Seal
1. Unthread (134) bolts, releasing (129) muffler assembly.
[C] = Carbon Steel
[Ck] = Ceramic
[D] = Acetal
2. Pull (135) valve block and components from (101) center body.
3. Remove (132) gasket, (141) valve plate and (140) valve insert
from (135) valve block.
[U] = Polyurethane
AIR MOTOR SECTION SERVICE
4. Remove (134) bolts, releasing (107 and 136) plugs and (111)
spool.
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.
Air Motor Section service is continued from Fluid Section repair.
y
MAJOR VALVE REASSEMBLY
PILOT VALVE DISASSEMBLY
1. Assemble new (139 and 138) “U” cups on (111) spool - LIPS
MUST FACE EACH OTHER.
2. Assemble (137) “O”rings to (136) large plug.
1. Remove (123) screws, releasing (103) covers, (121) washers,
(118) actuator pins and (167) pilot piston.
2. Remove (170) spool bushing and inspect inner bore of bushing
for damage.
3. Assemble (137 and 166) “O”rings to (107) small plug.
4. Insert (111) spool into (136) large plug, then insert (136) large
plug into (135) valve block, being sure the (111) spool is rotated
to accept (140) valve insert.
5. Assemble (107) small plug into (135) valve block.
6. 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 iden-
tification dot toward (132) gasket.
PILOT VALVE REASSEMBLY
1. Clean and lubricate parts not being replaced from service kit.
2. Assemble (171) “O” rings to (170) bushing and assemble bush-
ing into (101) center body.
3. Lubricate and assemble (167) pilot piston assembly into (170)
bushing.
4. Assemble (173 and 174) “O” rings and (121) washers to (103)
covers, then insert (118) actuator pins through assembly.
5. Assemble (144) “U” cups (note the lip direction) and (103) cov-
ers to (101) center body, securing with (123) screws. NOTE:
tighten (123) screws to 4 - 6 in. lbs (0.45 - 0.68 Nm).
7. Assemble (132 and 200) gaskets, (135) valve block and (129)
muffler assembly to (101) center body, securing with (134)
bolts. NOTE: Tighten (134) bolts to 15 - 20 in. lbs (1.7 - 2.3 Nm).
Page 8 of 12
PD05X-XXX-XXX-B (en)
PARTS LIST / PX05R-XXX-XXX-B AIR MOTOR SECTION
PILOT VALVE PARTS
637438 (optional)
c
c
c
c
144 118 169
168
171
232
130
129
201 (optional)
123
)
103L
c
173
c
174 121 167 170
140
132
107
137
166
129
c
c
c
144
135
134
138
103R
123
)
(
c
c
c
c
c
141
200
101
43
118 121 174
173
c
c
139
137
111
136
PILOT VALVE PARTS
g
76
Figure 4
MAJOR VALVE
ASSEMBLY TORQUE REQUIREMENTS
)
(
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(123) screw, 4 - 6 in. lbs (0.45 - 0.68 Nm).
(134) bolt, 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).
LUBRICATION / SEALANTS
Apply Lubriplate FML-2 grease to all “O” rings, “U” cups and mat-
ing parts.
c
g
Apply Loctite® 572™ to threads.
PD05X-XXX-XXX-B (en)
Page 9 of 12
TYPICAL CROSS SECTION
Models PE05A-XXS-XXX-B
Models PE05R-XXS-XXX-B
Figure 5
Page 10 of 12
PD05X-XXX-XXX-B (en)
TROUBLE SHOOTING
Product discharged from exhaust outlet.
y
y
Low output volume.
Check for diaphragm rupture.
Check tightness of (14) bolt.
Check air supply.
y
y
y
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 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-collapsing type, capable of pulling a high
volume.
Air bubbles in product discharge.
Check connections of suction plumbing.
Check “O”rings between intake manifold and fluid caps.
Check tightness of (14) bolt.
y
y
y
y
Motor blows air out main exhaust when stalled on either
stroke.
Check all joints on the inlet manifolds and suction connections.
These must be air tight.
Inspect the pump for solid objects lodged in the diaphragm
chamber or the seat area.
y
y
Check “U”cups on (111) spool in major valve.
Check (141) valve plate and (140) insert for wear.
Check (169) “U”cup on (167) pilot piston.
y
y
y
DIMENSIONAL DATA / PX05A-XXS-XXX-B
Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
Air Inlet 1/4 - 18 N.P.T.F. - 1
A
(Outlet) P
Q
E
L
F
G
N
B
D
K
R
S
M
H
C
J
P (Inlet)
(Inlet) P
DIMENSIONS
A - 8-7/32”(208.5 mm)
B - 11-1/16”(280.4 mm)
C - 6-1/8”(155.5 mm)
D - 2”(50.8 mm)
F
- 6”(152.4 mm)
L
- 4-5/16” (109.3 mm)
R - 3-1/16”(77.8 mm)
S - 1-1/4”(31.8 mm)
G - 11-3/4” (297.9 mm)
H - 4-7/8” (123.8 mm)
M - 3/8” (9.5 mm)
N - 6-5/16”(159.9 mm)
P - see below
J
- 5-1/2”(139.6 mm)
E
- 8-3/16”(207.9 mm)
K - 5/16” (7.9 mm)
Q - 8-1/8”(206.0 mm)
Pump Model
PX05A-AXS-XXX-B
PX05A-BXS-XXX-B
“P”Material Inlet / Outlet
1/2 - 14 N.P.T.F. - 1
Rp 1/2 (1/2 - 14 BSP, parallel)
Figure 6
PD05X-XXX-XXX-B (en)
Page 11 of 12
DIMENSIONAL DATA / PX05R-XXS-XXX-B
Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
Air Inlet 1/4 - 18 P.T.F. SAE Short
P (Outlet)
E
A
F
Q
L
B
N
G
D
K
R
M
H
C
J
P (Inlet)
DIMENSIONS
A - 7-11/16”(195.2 mm)
B - 11-1/16”(280.4 mm)
C - 6-1/8”(155.6 mm)
D - 2”(50.8 mm)
E
F
- 6-23/32”(170.6 mm)
- 6”(152.4 mm)
J
- 5-1/2”(139.7 mm)
N - 6-5/16”(160.0 mm)
P - see below
Q - 3-27/32”(97.6 mm)
R - 3-1/16”(77.8 mm)
K - 5/16”(7.9 mm)
G - 11-21/32”(296.0 mm)
H - 4-7/8”(123.8 mm)
L
- 1-1/4”(31.8 mm)
M - 3/8”(9.5 mm)
Pump Model
PX05R-AXS-XXX-B
PX05R-BXS-XXX-B
“P”Material Inlet / Outlet
1/2 - 14 N.P.T.F. - 1
Rp 1/2 (1/2 - 14 BSP, parallel)
Figure 7
PN 97999-1167
PD05X-XXX-XXX-B (en)
Page 12 of 12
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