Ingersoll Rand Water Pump PD03P XXX XXX User Manual

OPERATOR’S MANUAL  
PD03P-XXX-XXX  
RELEASED: 12-17-05  
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE  
REVISED:  
(REV. 05)  
5-13-10  
3/8” DIAPHRAGM PUMP  
1:1 RATIO, 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.  
637428 for air section repair (see page 6).  
637429-XX for fluid section repair (see page 4)  
.
PUMP DATA  
Models . . . . . . see Model Description Chart for “-XXX.  
Pump Type . . . Air Operated Double Diaphragm.  
Material . . . . . see Model Description Chart.  
Weight. . . . . . . . PD03P-XDS-XXX. . . . . . . 4.16 lbs (1.89 kgs)  
PD03P-XES-XXX. . . . . . . . 4.26 lbs (1.93 kgs)  
PD03P-XKS-XXX . . . . . . . 4.50 lbs (2.04 kgs)  
PD03P-XLS-XXX . . . . . . . 4.62 lbs (2.10 kgs)  
PD03P-XPS-XXX . . . . . . . 3.44 lbs (1.56 kgs)  
PD03P-XRS-XXX . . . . . . . 3.50 lbs (1.59 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.g. . . . . . . . 1 c.f.m /gallon (approx.)  
Figure 1  
(flooded inlet)  
Maximum Flow Rate  
MODEL DESCRIPTION CHART  
PD03  
Center Section Material  
- Polypropylene  
ball check. . . . . . . . . . . 10.6 g.p.m. (40.1 l.p.m.)  
duckbill . . . . . . . . . . . . . 8.7 g.p.m. (32.9 l.p.m.)  
X X  
P -X X S -X  
Displacement / Cycle @ 100 p.s.i.g  
ball check. . . . . . . . . . 0.022 gallons (0.083 lit.)  
P
duckbill . . . . . . . . . . . . . 0.018 gallons (0.068 lit.)  
Fluid Connection  
Maximum Particle Size  
A
B
- 3/8 - 18 N.P.T.F. - 1  
- Rp 3/8 (3/8 - 19 BSP)  
ball check. . . . . . . . . . 1/16dia. (1.6 mm)  
duckbill. . . . . . . . . . . . . fibers)  
Fluid Caps / Manifold Material  
D
E
K
L
P
R
- Groundable Acetal (single port)  
- Groundable Acetal (multiple port)  
- Kynar PVDF (single port)  
Maximum Temperature Limits (diaphragm / ball / seal material)  
Acetal . . . . . . . . . . . . . . . . . . . . . . -100 to 1800 F (-120 to 820 C)  
E.P.R / EPDM . . . . . . . . . . . . . . . . -600 to 2800 F (-510 to 1380 C)  
Hytrel . . . . . . . . . . . . . . . . . . . . . -200 to 1500 F (-29º to 660 C)  
Kynar P.V.D.F . . . . . . . . . . . . . . 100 to 2000 F (-12º to 930 C)  
Neoprene. . . . . . . . . . . . . . . . . . . 00 to 2000 F (-18º to 930 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)  
- Kynar PVDF (multiple port)  
- Polypropylene (single port)  
- Polypropylene (multiple port)  
Hardware Material  
- Stainless Steel  
S
Seat Material  
D
K
P
- Acetal  
S
0
- Stainless Steel  
- (Duckbill)  
- Kynar PVDF  
- Polypropylene  
PTFE . . . . . . . . . . . . . . . . . . . . . . 400 to 2250 F (40 to 1070 C)  
. . . . . . . . . . . . . . . . . . . . . -400 to 3500 F (-400 to 1770 C)  
Viton  
Ball Material  
(*) Duckbill models  
Groundable Models . . . . . . . . . PD03P-XDS-XXX  
PD03P-XES-XXX  
A
C
J
N
- Santoprene  
- Hytrel  
S
- Stainless Steel  
T
V
K
L
- PTFE  
- Viton  
- Nitrile (*)  
- Neoprene (*)  
Dimensional Data . . . . . . . . . . . . . . . . see page 8  
Noise Level @ 70 p.s.i., 60 c.p.m. . . . . . 72.7 db(A)  
- EPR (*)  
- Viton (*)  
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-PNEU-  
ROP S5.1 using four microphone locations.  
Diaphragm Material  
- Santoprene  
- Hytrel  
A
C
T
V
- PTFE / Santoprene  
- Viton  
NOTICE: All possible options are shown in the chart, however, cer-  
tain combinations may not be recommended, consult a represen-  
tative or the factory if you have questions concerning availability.  
FLUID SECTION SERVICE KIT SELECTION  
Example: Model # PD03P-ARS-SAA  
Fluid Section Service Kit # 637429-AA  
PD03P -ARS - S X X  
637429 - X  
X
Ball  
Diaphragm  
INGERSOLL RAND COMPANY LTD  
209 NORTH MAIN STREET – BRYAN, OHIO 43506  
© 2010  
CCN 15255995  
(800) 276-4658 FAX (800) 266-7016  
 
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.  
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 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.  
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Secure the diaphragm pump legs to a suitable surface to  
insure against damage by vibration.  
MAINTENANCE  
AIR AND LUBE REQUIREMENTS  
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 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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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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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.  
OPERATING INSTRUCTIONS  
Always flush the pump with a solvent compatible with  
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TYPICAL CROSS SECTION  
Figure 2  
Viton 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)  
®
®
PD03P-XXX-XXX (en)  
Page 3 of 12  
 
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PARTS LIST / PD03P-XXX-XXX FLUID SECTION  
637429-XX Fluid Section service kits include: 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® grease (page 6).  
n
SEAT OPTIONS  
PD03P-XXS-XXX  
BALL / DUCKBILL OPTIONS  
PD03P-XXS-XXX  
MATERIAL CODE  
[A] = Aluminum  
[B] = Nitrile  
[D] = Acetal  
[E] = E.P.R.  
“21”  
“22” (5/8” dia.)  
n
42”  
n
[GA] = Groundable Acetal  
[GFN] = Glass Filled Nylon  
[H] = Hytrel  
[K] = Kynar PVDF  
[N] = Neoprene  
[P] = Polypropylene  
[PPG] = Glass Filled  
Polypropylene  
-XXX Seat  
Qty [Mtl]  
-XXX Ball  
Qty  
[Mtl]  
-XXX Duckbill Qty [Mtl]  
-DXX 96580-2 (4)  
-KXX 96580-3 (4)  
-PXX 96580-1 (4)  
[D]  
[K]  
[P]  
-XAX 96481-A  
-XCX 96481-C  
-XSX 96513  
(4)  
(4)  
(4)  
(4)  
(4)  
[Sp]  
[H]  
-XJX 96744-2  
-XNX 96744-3  
-XLX 96744-4  
(4)  
(4)  
(4)  
[B]  
[N]  
[V]  
[E]  
[SS]  
[T]  
-SXX 96537  
-0XX 96745  
(4) [SS]  
(4) [P]  
-XTX 96481-4  
-XVX 96481-3  
-XKX 96744-1 (4)  
[Sp] = Santoprene  
[SS] = Stainless Steel  
[T] = PTFE  
[V]  
NOTE: Item 19 “Oring is not used with PD03P-XXX-0XX seat option.  
[V] = Viton  
DIAPHRAGM OPTIONS PD03P-XXS-XXX  
SERVICE KIT  
“7”  
“8”  
“19”  
n
n
n
n
-XX = (Ball)  
-XXX -XX = (Diaphragm) Diaphragm Qty [Mtl] Diaphragm Qty [Mtl]  
“O” Ring  
(3/32” x 1-1/8” o.d.)  
Qty  
[Mtl]  
[E]  
-XXA 637429-XA  
-XXC 637429-XC  
-XXT 637429-XT  
-XXV 637429-XV  
96533-A  
96533-C  
96538  
(2)  
(2)  
(2)  
(2)  
[Sp] -----  
[H] -----  
---  
---  
(2)  
---  
--- 93761  
(4)  
(4)  
(4)  
(4)  
--- Y325-119  
[Sp] 96514  
[B]  
[T] 96533-A  
[V] -----  
[T]  
96558  
--- Y327-119  
[V]  
MANIFOLD / FLUID CAP OPTIONS PD03P-XXS-XXX  
Polypropylene  
PD03P-XPS- PD03P-XRS-  
Qty Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No.  
Kynar PVDF  
PD03P-XKS- PD03P-XLS-  
Groundable Acetal  
PD03P-XDS-  
PD03P-XES  
(size)  
Item Description  
[Mtl] Part No.  
[Mtl]  
(1/4” - 20)  
6
Diaphragm Nut  
15 Fluid Cap  
43 Ground Strap  
(2) 93810-7 [P] 93810-7  
(2) 96460-1 [P] 96460-1  
[P] 93810-3 [K] 93810-3  
[P] 96460-3 [K] 96460-3  
[K] 93810-2  
[K] 96460-2  
--- 92956-1  
[D] 93810-2  
[GA] 96460-2  
[SS] 92956-1  
[D]  
[GA]  
[SS]  
(1) -----  
---  
-----  
---  
-----  
--- -----  
Ground Kit Assembly  
57  
(1) -----  
---  
-----  
---  
-----  
--- -----  
--- 66885-1  
[K] 96468-2  
66885-1  
(not shown)  
(N.P.T.F.)  
60 Inlet Manifold  
(1) 96468-1 [P] 96468-7  
[P] 96468-3 [K] 96468-9  
[GA] 96468-8  
[GA]  
(BSP)  
(1) 96468-4 [P] 96468-10 [P] 96468-6 [K] 96468-12 [K] 96468-5  
[GA] 96468-11 [GA]  
(N.P.T.F.)  
(BSP)  
61 Outlet Manifold  
(1) 96469-1 [P] 96469-1  
(1) 96469-4 [P] 96469-4  
[P] 96469-3 [K] 96469-3  
[P] 96469-6 [K] 96469-6  
[K] 96469-2  
[K] 96469-5  
[K] -----  
[GA] 96469-2  
[GA] 96469-5  
--- 94478-2  
--- 96559-2  
[GA]  
[GA]  
[D]  
(N.P.T.F.)  
[PPG]  
[PPG]  
63 Pipe Plug  
(1) -----  
(1) -----  
---  
---  
94478-1  
96559-1  
-----  
-----  
--- 94478-3  
--- 96559-3  
(BSP)  
[K] -----  
[D]  
COMMON PARTS  
Item Description (size)  
Qty  
Part No. [Mtl]  
Item  
27 Bolt  
29  
Description (size)  
(1/4” - 20 x 1-1/8”)  
Qty Part No.  
(12) 96471  
(20) 93828  
(2) 93264  
[Mtl]  
1
5
Connecting Rod  
Diaphragm Washer  
(1/4” - 20 x 1-1/8”)  
(1)  
(2)  
(8)  
96532  
96556  
96471  
[SS]  
[GFN]  
[SS]  
[SS]  
[SS]  
[A]  
o
(1/4” - 20)  
Nut  
26 Bolt  
77 Logo Plate  
DUAL INLET / DUAL OUTLET KITS 637442-X  
Polypropylene  
Kynar PVDF  
Groundable Acetal  
637442-1 (N.P.T.) 637442-4 (BSP) 637442-3 (N.P.T.) 637442-6 (BSP) 637442-2 (N.P.T.) 637442-5 (BSP)  
Qty Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl] Part No. [Mtl]  
(size)  
Item Description  
17 Dual Outlet Manifold  
18 Dual Inlet Manifold  
(2) 96520-1 [P] 96520-4  
(2) 96519-1 [P] 96519-4  
[P] 96520-3 [K]  
[P] 96519-3 [K]  
96520-6  
96519-6  
96514  
[K] 96520-2 [GA] 96520-5 [GA]  
[K] 96519-2 [GA] 96519-5 [GA]  
(3/32” x 1-1/8” o.d.)  
19 O” Ring  
(1) 96514  
[T] 96514  
[T] 96514  
[T]  
[T] 96514  
[T] 96514  
[T]  
Smart Partskeep 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  
PD03P-XXX-XXX (en)  
 
PARTS LIST / PD03P-XXX-XXX FLUID SECTION  
COLOR CODE  
3
2
1
4
DIAPHRAGM BALL  
MATERIAL  
COLOR  
COLOR  
Hytrel  
Cream  
Tan  
Black (  
Tan  
)
Santoprene  
5
6
Viton  
Yellow ( )  
Yellow ( )  
) Dot  
(
17  
Torque Sequence  
FOR THE  
AIR MOTOR SECTION  
SEE PAGES 6 & 7  
61  
29  
43  
1
7
22  
21  
19  
26  
29  
42  
21  
77  
15  
26  
22  
21  
19  
27  
5
63  
6
42  
21  
60 (PD03P-XES-XXX,  
PD03P-XLS-XXX,  
PD03P-XRS-XXX)  
29  
Stainless steel seat installation  
60 (PD03P-XDS-XXX,  
Radius (ball side)  
PD03P-XKS-XXX,  
PD03P-XP  
S-XXX)  
18  
Chamfer(fluid inlet side)  
View for PD03P-XXS-XXT (PTFE diaphragm)  
configuration only  
Figure 3  
PTFE(white)  
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ASSEMBLY TORQUE REQUIREMENTS  
NOTE: DO NOT OVERTIGHTEN FASTENERS.  
(6) diaphragm nut, 60 - 70 in. lbs (6.8 - 7.9 Nm).  
(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 (94276) to all “O" rings, ”U" cups and mating parts.  
Apply pipe sealant to threads.  
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.  
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Air Side Santoprene (tan)  
PD03P-XXX-XXX (en)  
Page 5 of 12  
 
PARTS LIST / PD03P-XXX-XXX AIR MOTOR SECTION  
p
Indicates parts included in 637428 Air Section Repair Kit.  
Item  
101 Center Body  
Description (size)  
Qty Part No.  
(1) 96466  
[Mtl]  
[PPG]  
Item  
140 Valve Insert  
Description (size)  
Qty Part No. [Mtl]  
(1) 93276  
(1) 96173  
[CK]  
[CK]  
(right side)  
103R Cover  
103L Cover  
(1) 96488  
(1) 96489  
(1) 96353  
(1) 95919  
(2) 94874-1  
(2) 96092  
(12) 96093  
(1) 96542  
(1) 95931  
(1) 96214-1  
(4) 96487  
(1) 96204  
(1) 96352  
(3) Y325-29  
(1) 94395  
(1) 96383  
[D]  
[D]  
141 Valve Plate  
(left side)  
(1/8” x 3/4” o.d.)  
144 “U” Cup Packing  
(2) Y187-47 [B]  
(1) Y325-24 [B]  
p
p
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  
(1) 67382  
(2) 96459  
(1) 96384  
(1) 96090  
[D]  
[U]  
[U]  
[D]  
(1/16” x 7/16” o.d.)  
168 “O” Ring  
[SS]  
[D]  
(1/8” x 5/8” o.d.)  
169 “U” Cup Packing  
170 Spool Bushing  
p
p
(#4 - 20 x 1/2”)  
123 Screw  
[SS]  
[P]  
(1/16” x 13/16” o.d.)  
129 Muffler Baffle  
130 Gasket  
171 “O” Ring  
173 “O” Ring  
174 “O” Ring  
(2) Y325-17 [B]  
(2) Y325-115 [B]  
(2) Y325-105 [B]  
p
p
p
p
p
(3/32” x 7/8” o.d.)  
(3/32” x 11/32” o.d.)  
[SY]  
[B]  
132 Air Manifold Gasket  
(1/4” - 20 x 3”)  
134 Flange Bolt  
135 Valve Block  
136 Plug, Large  
[SS]  
[PPG]  
[D]  
200 Porting Gasket  
(1) 96364  
[B]  
(1/16” x 3/8” o.d.)  
232 “O” Ring  
(4) Y325-10 [P]  
(4) Y12-4-S [SS]  
(1/4” - 20)  
236 Nut  
(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, 10 Pack  
MATERIAL CODE  
AIR MOTOR SECTION SERVICE  
[B] = Nitrile  
[CK] = Ceramic  
[D] = Acetal  
[PPG] = Glass Filled Polypropylene  
[SS] = Stainless Steel  
[SY] = Syn-Seal  
Service is divided into two parts - 1. Pilot Valve, 2. Major  
Valve.  
[P] = Polypropylene  
[U] = Polyurethane  
Air Motor Section Service is continued from Fluid Section  
repair.  
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DIAPHRAGM PUMP SERVICE  
GENERAL SERVICE NOTES:  
PILOT VALVE DISASSEMBLY  
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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1. Remove (123) screws, releasing (103) covers, (121) wash-  
ers, (118) actuator pins and (167) pilot piston.  
2. Remove (170) spool bushing and inspect inner bore of  
bushing for damage.  
Tools needed to complete disassembly and repair:  
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5/8” socket or wrench, 7/16” socket or wrench, 3/8”  
socket or wrench, 5/16” Allen wrench, T-10 Torx  
screwdriver, torque wrench (measuring inch pounds),  
“Oring pick.  
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PILOT VALVE REASSEMBLY  
1. Clean and lubricate parts not being replaced from ser-  
vice kit.  
2. Assemble (171) “O” rings to (170) bushing and assemble  
bushing 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 as-  
sembly.  
5. Assemble (144) “U” cups (note the lip direction) and (103)  
covers to (101) center body, securing with (123) screws.  
NOTE: Tighten (123) screws to 4 - 6 in. lbs (0.45 - 0.68 Nm).  
FLUID SECTION DISASSEMBLY  
1. Remove (61) top manifold.  
2. Remove (19) “Orings, (21) seats and (22) balls.  
3. Remove (60) bottom manifold.  
4. Remove (19) “Orings, (21) seats and (22) balls.  
5. Remove (15) fluid caps.  
6. Remove (6) diaphragm nut, (7) or (7 / 8) diaphragms and  
(5) washer.  
7. Remove (1) connecting rod from air motor.  
8. Carefully remove remaining (6) diaphragm nut, (7) or (7 / 8)  
diaphragms and (5) washer from (1) connecting rod. Do  
not mar surface of connecting rod.  
MAJOR VALVE DISASSEMBLY  
1. Unthread (123) screws, releasing (129) muffler baffle.  
2. Unthread (134) bolts and pull (135) valve block and com-  
ponents from (101) center body.  
3. Remove (132) gasket, (141) valve plate and (140) valve  
insert from (135) valve block.  
4. Remove (134) bolts, releasing (107 and 136) plugs and  
(111) spool.  
FLUID SECTION REASSEMBLY  
Reassemble in reverse order.  
Lubricate (1) connecting rod with Lubriplate or equiva-  
lent “Oring lubricant.  
Install (5) washers with i.d. chamfer toward diaphragm.  
When replacing PTFE diaphragms, install the 96533-A  
Santoprene diaphragm behind the Teflon diaphragm.  
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Page 6 of 12  
PD03P-XXX-XXX (en)  
 
PARTS LIST / PD03P-XXX-XXX AIR MOTOR SECTION  
PILOT VALVE PARTS  
144 118  
169 168 171  
123  
103L  
173  
232  
236 130 129  
174  
121 167 170  
140 132  
107  
137  
166  
123  
144  
103R  
123  
135  
134  
138  
141  
200  
101  
118 121 174 173  
PILOT VALVE PARTS  
139  
137  
111  
136  
ASSEMBLY TORQUE REQUIREMENTS  
NOTE: DO NOTOVERTIGHTEN FASTENERS.  
(123) screw, 4 - 6 in. lbs (0.45 - 0.68 Nm).  
(134)bolt, 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).  
MAJOR VALVE  
LUBRICATION / SEALANTS  
Apply Lubriplate (94276) to all “O" rings, ”U" cups and mating parts.  
Figure 4  
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 identification dot toward (132) gasket.  
7. Assemble (132 and 200) gaskets and (135) valve block  
to (101) center body, securing with (134) bolts. NOTE:  
Tighten (134) bolts to 15 - 20 in. lbs (1.7 - 2.3 Nm).  
8. Assemble (130) gasket and (129) muffler baffle to (101)  
center body, securing with (123) screws. NOTE: Tighten  
(123) screws to 4 - 6 in. lbs (0.45 - 0.68 Nm).  
MAJOR VALVE REASSEMBLY  
1. Assemble new (139 and 138) U” cups on (111) spool -  
LIPS MUST FACE EACH OTHER.  
2. Assemble (137) Orings to (136) large plug.  
3. Assemble (137 and 166) Orings 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.  
PD03P-XXX-XXX (en)  
Page 7 of 12  
 
TROUBLE SHOOTING  
Pump blows air out main exhaust when stalled on either  
stroke.  
Product discharged from air exhaust.  
Check for diaphragm rupture.  
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Check air supply.  
Check tightness of (6) diaphragm nut.  
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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 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 non-collapsible type, capable 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 (6) diaphragm nut.  
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Pump blows air out main exhaust when stalled on either  
stroke.  
Check all joints on intake manifolds and suction connec-  
tions. These must be airtight.  
Inspect the pump for solid objects lodged in the dia-  
phragm chamber or the seat area.  
Check “Ucups on (111) spool in major valve.  
Check (141) valve plate and (140) insert for wear.  
Check (169) Ucup on (167) pilot piston.  
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DIMENSIONAL DATA  
Dimensions shown are for reference only, they are shown in inches and millimeters (mm).  
Air Inlet 1/4 - 18 P.T.F. SAE Short  
7-31/32"(202.3 mm)  
4-13/32"(110.5 mm)  
Exhaust Port 1/2 - 14 N.P.T.F. - 1  
5-23/32" (145.2 mm)  
4-31/32"(125.6 mm)  
9-5/16"  
(236.2 mm)  
8-17/32"  
(216.1 mm)  
4-3/8"  
(111.0 mm)  
1-3/32"  
(27.8 mm)  
1-9/32"  
(32.1 mm)  
9/32" Slot  
2-13/16"  
3/8"(9.6 mm)  
4-1/16"(102.7 mm)  
4-13/16"(121.9 mm)  
(7.2 mm)  
(71.4 mm)  
5-5/8" (142.7 mm)  
Pump Model  
“A" Material Inlet  
“B" Material Outlet  
PD03P-AXS-XXX  
PD03P-BXS-XXX  
3/8 - 18 N.P.T.F.  
Rp 3/8 (3/8 - 19 BSP, parallel)  
3/8 - 18 N.P.T.F. - 1  
Rp 3/8 (3/8 - 19 BSP, parallel)  
Figure 5  
Page 8 of 12  
PD03P-XXX-XXX (en)  
 
ACCESSORIES  
67388 WALL MOUNT BRACKET ASSEMBLY  
96507 Wall Mount Bracket  
Y13-3-T Washer (3) (3/16")  
(#10)  
Y14-10-S Lock Washer (3)  
Y154-52-S Cap Screw (3)  
(#10 - 24 x 1/2")  
Figure 6  
PD03P-XXX-XXX (en)  
Page 9 of 12  
 
Page 10 of 12  
PD03P-XXX-XXX (en)  
 
PD03P-XXX-XXX (en)  
Page 11 of 12  
 
PN 97999-1180  
Page 12 of 12  
PD03P-XXX-XXX (en)  
 

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