Ingersoll Rand Water Pump 66605X X User Manual

66605X-X  
OPERATOR’S MANUAL  
RELEASED: 4-15-87  
REVISED:  
(REV. AR)  
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE  
5-28-10  
1/2” 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.  
637140-XX for fluid section repair (see page 4).  
637141 for air section repair (see page 6).  
PUMP DATA  
Models . . . . . . . . . . see Model Description Chart for “-XXX”.  
Pump Type . . . . . . . Non-MetallicAir Operated DoubleDiaphragm  
Material . . . . . . . . . . see Model Description Chart.  
Weight . . . . Polypropylene . . . . . . . . . 7.2 (3.3 kgs)  
Groundable Acetal . . . . . . 8.8 (4.0 kgs)  
KynarR PVDF . . . . . . . . . 9.5 (4.3 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)  
66605J-XXX  
66605H-XXX  
66605K-XXX  
666053-XXX  
666056-XXX  
666057-XXX  
Maximum Outlet Pressure . . . . . . . . . . 100 p.s.i.g. (6.9 bar)  
Air Consumption . . . . . . . . . . . . . . . . . 1 c.f.m. / gallon (approx.)  
Figure 1  
Maximum Flow Rate  
(Ball) . . . . . . . 13 g.p.m. (49.2 l.p.m.)  
(Duckbill) . . . . 10 g.p.m. (37.9 l.p.m.)  
MODEL DESCRIPTION CHART  
Maximum Particle Size (Ball) . . . . . . . 3/32” dia. (2.4 mm)  
(Duckbill) . . . . Fibers  
66605 X - X X X - 04  
Maximum Temperature Limits  
E.P.R. . . . . . . . . . . . . . . . . -60_ to 280_ F (-51_ to 138_ C)  
Groundable Acetal . . . . . . . 10_ to 180_ F (-12_ to 82_ C)  
HytrelR . . . . . . . . . . . . . . -20_ to 150_ F (-29_ to 66_ C)  
Neoprene . . . . . . . . . . . . . 0_ to 200_ F (-18_ to 93_ 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)  
Kynar PVDF . . . . . . . . . . . 10_ to 200_ F (-12_ to 93_ C)  
SantopreneR . . . . . . . . . . -40_ to 225_ F (-40_ to 107_ C)  
PTFE . . . . . . . . . . . . . . . . 40_ to 225_ F (4_ to 107_ C)  
VitonR . . . . . . . . . . . . . . . -40_ to 350_ F (-40_ to 177_ C)  
Groundable . . . . . . . . . . . 666056-X and 66605H-X models only  
Dimensional Data . . . . . . . . . . . . . . . . see page 8  
Noise Level @ 70 p.s.i., 60 c.p.m. . . . . . 71.1 db(A)  
Fluid Caps & Manifold Material  
3 - Piece Manifold  
3 - Polypropylene  
6 - Groundable Acetal  
7 - Pure Kynar  
Single Piece Manifold  
J - Polypropylene  
H - Groundable Acetal  
K - Pure Kynar  
Seat Material  
0 - (Duck Bill)  
4 - Kynar PVDF  
6 - Acetal  
2 - Stainless Steel  
3 - Polypropylene  
Ball Material  
1 - Neoprene  
2 - Nitrile  
( * ) Duckbill models  
8 - Polyurethane  
A - Stainless Steel  
C - Neoprene (*)  
D - Nitrile (*)  
3 - Viton  
4 - PTFE  
5 - E.P.R.  
E - Santoprene  
*
The pump sound pressure levels published here have been updated to an Equivalent  
Diaphragm Material  
1 - Neoprene  
Continuous Sound Level (L ) to meet the intent of ANSI S1.13-1971, CAGI-PNEU-  
Aeq  
5 - E.P.R.  
ROP S5.1 using four microphone locations.  
2 - Nitrile  
3 - Viton  
8 - Polyurethane  
9 - Hytrel  
NOTICE:Allpossibleoptionsareshowninthecharthowevercertaincom-  
binations may not be recommended, consult a representative or the fac-  
tory if you have questions concerning availability.  
4 - PTFE / Santoprene  
B - Santoprene  
Cone Check Flow  
04 - Top Discharge  
FLUID SECTION SERVICE KIT SELECTION  
66605X - X X X  
637140 - X X  
EXAMPLE: MODEL # 666053-321  
Fluid Section Service Kit # 637140-21  
Ball  
Diaphragm  
INGERSOLL RAND COMPANY LTD  
209 NORTH MAIN STREET – BRYAN, OHIO 43506  
© 2010  
(800) 495-0276 FAX(800) 892-6276  
CCN 99449712  
 
GENERAL DESCRIPTION  
MAINTENANCE  
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.  
Refertothepartviewsanddescriptionsasprovidedonpage4through7  
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.  
Air operated double diaphragm pumps utilize a pressure differential in  
theairchamberstoalternatelycreatesuctionandpositivefluidpressure  
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 pres-  
sure and will stop cycling once maximum line pressure is reached (dis-  
pensing device closed) and will resume pumping as needed.  
Models 666056-X and 66605H-X: The Acetal material used in these  
pumpscontainsstainlesssteelfibers.It’sconductivityallowsittobecon-  
nected to a suitable ground. A ground screw and ground wire kit is pro-  
vided for this.  
S 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 active MATERIAL OPTIONS.  
S Provide a clean work surface to protect sensitive internal moving  
partsfromcontaminationfromdirtandforeignmatter duringservice  
disassembly and reassembly.  
S Keep good records of service activity and include pump in preven-  
tive maintenance program.  
DUCKBILL CHECK VALVES (OPTIONAL)  
Pumpmodelswiththesuffix(-0CXor-0DX)comeequippedwithduckbill  
typechecks.Standardduckbillpumpsareshippedwiththematerialinlet  
in the top and the material outlet on the bottom manifold. To change the  
directionofflow, disassemblethepumpasinstructedintheFLUIDSEC-  
TIONandreassembleasdescribedbelow. Apumpthatwasfactorybuilt  
withballsandseatscanberetro-fittedwithduckbilltypecheckvalvesby  
purchasing the necessary parts and installing them as shown.  
Reassembly:  
Theduckbillsmaybeinstalledineitherdirectiontoproduceflowfromtop  
to bottom of the pump or from bottom to top of the pump. In either case,  
all of the (42) duckbills must point in the same direction.  
Flow from Top to Bottom: (see page 5)  
AIR AND LUBE REQUIREMENTS  
WARNING EXCESSIVE AIR PRESSURE. Can cause pump  
damage, personal injury or property damage.  
S Afiltercapableoffilteringoutparticleslargerthan50micronsshould  
beusedontheairsupply. Thereisnolubricationrequiredotherthan  
the “O” ring lubricant which is applied during assembly or repair.  
S Iflubricatedairispresent,makesurethatitiscompatiblewiththeO”  
rings and seals in the air motor section of the pump.  
OPERATING INSTRUCTIONS  
1. With (15) fluid caps installed, stand the pump upside down.  
2. Place (21) insert into (42) duckbill and slide (41) sleeve over (42)  
duckbill.  
S Always flush the pump with a solvent compatible with the material  
beingpumpedifthematerialbeing pumpedissubjectto “settingup”  
when not in use for a period of time.  
S Disconnecttheairsupplyfromthepumpifitistobeinactiveforafew  
hours.  
S Theoutletmaterialvolumeisgovernednotonlybytheairsupplybut  
alsobythematerialsupplyavailableattheinlet.Thematerialsupply  
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 forced-feed (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.  
3. Slide the complete check assembly into the fluid cap bore with the  
(21) insert end first. [Duckbills (42) point up.]  
4. Position (19) “O” ring over (41) sleeve.  
5. Attach (35) manifold feet / (36) swivel assembly to the fluid caps.  
6. Turn pump over to right side up position.  
7. Assemble duckbill check as in step #1.  
8. Slide the complete check assembly into the fluid cap bore with the  
(41) sleeveendfirst. [Duckbillis pointingdown towardfluid capcav-  
ity.]  
9. Position (19) “O” ring around (21) insert.  
10. Attach (34) manifold / (36) swivel assembly to fluid cap.  
Flow from Bottom to Top: (Inlet Bottom - Outlet Top)  
Toreverseflowdirection, slidecheckvalveassembliesintothe(15)fluid  
capsbackwardsfromwhatisindicatedinsteps#2and#7.Instep#2,the  
(42) duckbills will be pointing down and in step #7, they will be pointing  
up.  
S VitonR and HytrelR are registered trademarks of the DuPont Company S KynarR is a registered trademark of Arkema Inc. S FluorazR is a registered trademark of Greene, Tweed & Co. Inc. S  
S SantopreneR is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. S  
66605X-X (en)  
Page 3 of 8  
 
PARTS LIST / 66605X-X FLUID SECTION  
l 637140-XX Fluid Section Service Kits include: Balls (see “BALL OPTIONS”, refer to -XX in chart below), Diaphragms (see “DIAPHRAGM OPTIONS”,  
refer to -XX in chart below), plus “O” ring items: 2, 19, 20, 33 and 93706-1 Key-Lube grease (page 6).  
SEAT OPTIONS  
ITEM “21”  
BALL OPTIONS  
ITEM “22” (3/4” dia.) (Service Kit -XX)  
MATERIAL CODE  
[B] = Nitrile  
[D] = Acetal  
-XXX  
Seat  
Qty [Mtl]  
(4) [SS]  
-XXX  
Ball  
Qty [Mtl]  
-XXX  
Ball  
Qty [Mtl]  
(4) [SS]  
[E] = E.P.R.  
[F] = Fluoraz  
-2XX  
-3XX  
93409-1  
93098-1  
93098-10  
93098-4  
93098-3  
93115-1  
-X1X  
-X2X  
-X3X  
-X4X  
93100-1  
93100-2  
93100-3  
93100-4  
(4)  
(4)  
(4)  
(4)  
[N]  
[B]  
[V]  
[T]  
-XAX  
-XEX  
93410-1  
93100-E  
[GA] = Groundable Acetal  
[GFN] =Glass Filled Nylon  
[H] = Hytrel  
(4)  
(4)  
[P]  
[P]  
(4)  
[Sp]  
-34X / -3AX  
-4XX  
[N] = Neoprene  
[P] = Polypropylene  
[PK] = Pure Kynar  
[Sp] = Santoprene  
[SS] = Stainless Steel  
[T] = PTFE  
(4) [PK]  
-0XX  
ITEM “42” (Duckbill)  
-6XX  
(4)  
(4)  
[D]  
[P]  
-X5X  
-X8X  
93100-5  
93100-8  
(4)  
(4)  
[E]  
[U]  
-0CX  
-0DX  
93114-1  
93114-2  
(4)  
(4)  
[N]  
[B]  
-0XX  
[U] = Polyurethane  
[V] = Viton  
DIAPHRAGM OPTIONS  
“7” / “8”  
l Service Kits  
“19”  
“20”  
“33” K  
-XX = (Ball or Duckbill)  
-XX = (Diaphragm)  
“O” Ring (4)  
[Mtl] 1-5/16” o.d.  
“O” Ring (2)  
1-1/8” o.d.  
“O” Ring (4)  
1-3/16” o.d.  
66605X-XXX  
Diaphragm (2)  
[Mtl]  
-XX1  
-XX2  
-XX3  
637140-X1  
637140-X2  
637140-X3  
93113  
93465-G  
93581-3  
[N]  
[B]  
[V]  
Y325-122  
Y325-122  
Y327-122  
Y325-119  
Y325-119  
Y327-119  
Y328-119  
93933  
Y325-120  
Y325-120  
Y327-120  
94749  
[B]  
[B]  
[V]  
[T]  
[F]  
[T]  
[E]  
[U]  
[B]  
[E]  
H
Not shown  
666053-, 66605J-XX4 637140-X4  
666056-, 66605H-XX4 637140-X4  
666057-, 66605K-XX4 637140-X4  
93111 / 93465  
93111 / 93465  
93111 / 93465  
93760  
[T/Sp] 93265  
[T/Sp] 93764  
[T/Sp] 93265  
s Quantity = 22  
95129  
Y328-119  
93761  
94749  
-XX5  
-XX8  
-XX9  
-XXB  
637140-X5  
637140-X8  
637140-X9  
637140-XB  
[E]  
[U]  
[H]  
93763  
93762  
93112  
93119  
93117  
93118  
93465-9  
Y325-122  
Y325-119  
93761  
Y325-120  
93762  
93465  
[Sp] 93763  
-0X1  
-0X2  
-0X4  
-0X8  
-0XB  
637140-C1, D1  
637140-C2, D2  
637140-C4, D4  
637140-C8, D8  
637140-CB, DB  
93113  
[N]  
[B]  
Y325-122  
Y325-122  
Not Req’d  
Not Req’d  
Not Req’d  
Not Req’d  
Not Req’d  
Y325-120  
Y325-120  
94749  
[B]  
[B]  
[T]  
[U]  
[B]  
93465-G  
93111 / 93465  
93112  
[T/Sp] Y325-122  
[U] 93119  
[Sp] Y325-122  
93118  
93465  
Y325-120  
K
Item “33” “O” rings are not used on models 66605H-XXX, 66605J-XXX and 66605K-XXX.  
WETTED COMMON PARTS  
Polypropylene  
666053-XXX 66605J-XXX  
Part No. Mtl  
[SS] 93084 [SS] 93084  
Groundable Acetal  
Pure Kynar  
666056-XXX  
Part No. Mtl  
[SS] 93084  
66605H-XXX  
666057-XXX  
Part No. Mtl  
[SS] 93084 [SS] 93084  
66605K-XXX  
Item Description (size)  
Qty Part No.  
Mtl  
Part No.  
Mtl  
Part No.  
Mtl  
V 1 Rod  
(1) 93084  
(1) Y325-111  
(2) 94645  
(2) 93103-1  
(2) 93105-1  
(8) 93109  
(2) - - - - -  
[SS]  
[B]  
2
5
“O” Ring (3/32” x 5/8” o.d.)  
Washer (2” o.d.)  
[B]  
Y325-111  
[B]  
Y325-111  
[B]  
Y325-111  
[B]  
Y325-111  
[B]  
Y325-111  
[GFN] 94645  
[GFN] 94645  
[GFN] 94645  
[GFN] 94645  
[GFN] 94645  
[PK] 93103-4  
[PK] 93105-9  
[SS] 93109  
[GFN]  
[PK]  
[PK]  
[SS]  
- - -  
V 6 Diaphragm Nut (5/16” - 18)  
15 Fluid Cap (includes 26 & 124)  
26 Bolt (5/16” - 18 x 1-1/2”)  
29 Nut (5/16” - 18)  
[P]  
[P]  
93103-1  
93105-1  
[P]  
[P]  
93103-3  
[D]  
93103-3  
[D]  
93103-4  
93105-11  
[GA] 93105-11 [GA] 93105-9  
[SS] 93109  
[SS] 93109  
[SS] 93109  
[SS] Y12-5-S  
[GA] - - - - -  
[GA] - - - - -  
[GA] - - - - -  
[SS] - - - - -  
[SS] 93109  
[SS] - - - - -  
- - -  
[P]  
[P]  
[P]  
- - - - -  
- - - - -  
- - - - -  
- - - - -  
- - -  
- - -  
- - -  
- - -  
- - -  
- - -  
- - -  
[P]  
[P]  
- - -  
- - -  
[P]  
[P]  
Y12-5-S  
93102-6  
93106-6  
93101-6  
93099  
- - -  
- - - - -  
34 Manifold, Outlet (top)  
V 35 Manifold, Foot (bottom)  
V 36 Swivel  
(2) 93102-1  
(2) 93106-1  
(2) 93101-1  
(8) 93099  
- - -  
- - -  
- - -  
- - -  
- - -  
- - -  
[D]  
- - -  
93102-4  
93106-4  
93101-4  
93099  
[PK] - - - - -  
[PK] - - - - -  
[PK] - - - - -  
[SS] - - - - -  
- - -  
- - -  
- - -  
V 37 Clamp  
[SS] - - - - -  
- - -  
38 Bolt (#10 - 24 x 1-1/2”)  
39 Nut (#10 - 24)  
(8) Y84-303-T [SS] - - - - -  
Y84-303-T [SS] - - - - -  
Y84-303-T [SS] - - - - -  
- - -  
(8) Y22-10-S  
(4) 93097-1  
(4) 93120-1  
(1) - - - - -  
(1) - - - - -  
(1) - - - - -  
(1) - - - - -  
(24) 93886  
(6) - - - - -  
[SS] - - - - -  
Y22-10-S  
93097-3  
- - - - -  
[SS] - - - - -  
Y22-10-S  
93097-4  
- - - - -  
[SS] - - - - -  
- - -  
41a Ball Cage  
[P]  
[P]  
- - -  
- - -  
- - -  
- - -  
93097-1  
[D]  
- - -  
93097-3  
- - - - -  
[PK] 93097-4  
[PK]  
- - -  
41b Sleeve (models 66605X-0XX)  
43 Ground Strap  
93120-1  
- - - - -  
- - -  
- - -  
- - -  
- - -  
- - -  
- - - - -  
92956-1  
66885-1  
- - - - -  
[SS] 92956-1  
[SS] - - - - -  
- - - - - - - -  
- - - - -  
- - -  
H 57 Ground Kit Assembly  
60 Manifold, Inlet (bottom)  
61 Manifold, Outlet (top)  
62 Flange Nut (5/16” - 18)  
63 Plug (1/2 - 14 N.P.T.)  
- - - - -  
- - -  
- - -  
- - -  
66885-1  
93802-2  
93801-2  
- - - - -  
- - -  
93802-1  
93801-1  
[GA] - - - - -  
[GA] - - - - -  
93802-3  
93801-3  
[PK]  
[PK]  
[SS]  
[PK]  
- - - - -  
[SS] 93886  
- - - 93897-1  
[SS] 93886 (s)  
[P] - - - - -  
[SS] 93886 (s) [SS] 93886  
- - - 93897-2 [D] - - - - -  
[SS] 93886  
- - - 93897-3  
V “Smart Parts”, keep these items on hand in addition to the service kits for fast repair and reduction of down time.  
Page 4 of 8  
66605X-X (en)  
 
PARTS LIST / 66605X-X FLUID SECTION  
COLOR CODE  
Diaphragm  
Color  
Ball  
Color  
Orange  
Red (S)  
Blue (S)  
N/A  
Green (S)  
Tan  
White  
Red  
Material  
61  
Acetal  
N/A  
Red (--)  
Blue (--)  
Cream  
Green (--)  
Tan  
White  
Clear  
Yellow (--)  
(--) Stripe  
Nitrile  
63 ,  
E.P.R.  
Hytrel  
OUTLET  
Neoprene  
Santoprene  
PTFE  
66605X-0XX-04  
Polyurethane  
Viton  
Yellow (S)  
(S) Dot  
38  
37  
FOR THE  
AIR MOTOR SECTION  
SEE PAGES 6 & 7  
19  
21  
19  
36  
33  
. 62  
34  
41b  
42  
42 k  
. 39  
19  
41a  
22  
20  
21  
26  
41b  
21  
OUTLET  
124  
15  
62 ,  
2
1
29 ,  
5
8
43  
7 Y  
6 ,  
26  
21  
41b  
42  
41a  
22  
21  
19  
35  
k 42  
36  
33  
41b  
19  
21  
19  
66605X-0XX-04  
INLET  
k
Y
When duckbills face down, the inlet is on the top.  
Used on 66605X-XX4 (PTFE) models only.  
. TORQUE REQUIREMENTS ,  
NOTE: DO NOT OVERTIGHTEN FASTENERS.  
(6) Diaphragm nut, 95 - 105 in. lbs (10.7 - 11.9 Nm).  
(29, 62) Fluid cap / manifold nuts, 50 -60 in. lbs (5.6 -6.8 Nm), /alternately  
and evenly, then re-torque after initial run-in.  
(39) Nuts, 20 - 25 in. lbs (2.3 - 2.8 Nm) then re-torque.  
(63) Plugs, 25 in. lbs (2.8 Nm) maximum.  
60  
63 ,  
LUBRICATION / SEALANTS  
Apply Key-Lube (93706-1) to all “O” rings, “U” cups and mating parts.  
Figure 2  
66605X-X (en)  
Page 5 of 8  
 
PARTS LIST / 66605X-X AIR MOTOR SECTION  
n Indicates parts included in 637141 Air Section Repair Kit.  
AIR SECTION PARTS  
Item Description (size)  
101 Motor Body  
Qty Part No.  
(1) 93091  
(2) Y325-117  
(1) 93087  
(2) 37285  
(1) 93085  
(1) 93088  
(4) 93075  
(3) 115959  
(2) 77802  
(8) 93249  
(1) 66972  
93092  
[Mtl]  
Item Description (size)  
Qty Part No.  
(4) 93096  
(4) Y6-419-T  
(1) 93090  
(1) 93086  
(1) Y325-125  
(1) 94395  
(1) 96383  
(1) 93276  
(1) 93275  
(2) 116038  
(2) 93089  
93110  
[Mtl]  
[SS]  
[SS]  
[P]  
[P]  
133 Washer (9/32” i.d.)  
134 Bolt (1/4” - 20 x 5”)  
135 Valve Block  
n 102 “O” Ring (3/32” x 1” o.d.)  
j 103 Sleeve  
[B]  
[Bz]  
[C]  
j 104 Snap Ring (13/16”)  
111 Spool  
136 Plug  
[D]  
[D]  
n 137 “O” Ring (3/32” x 1-1/2” o.d.)  
n 138 Packing, “U” Cup (1/8” x 1” o.d.)  
n 139 Packing, “U” Cup (1/8” x 1.427” o.d.)  
n 140 Valve Insert  
[B]  
118 Pilot Rod  
[C]  
[U]  
n 119 “O” Ring (1/8” x 3/4” o.d.)  
j 120 Spacer  
[U]  
[B]  
[Z]  
[CK]  
[CK]  
[Z]  
n 122 Snap Ring (1/2”)  
124 Stud (5/16” - 18 x 1-17/32”) (see page 5)  
129 Muffler Assembly  
129l Exhaust Cover (see note 2)  
n 130 Gasket  
[C]  
n 141 Valve Plate  
[SS]  
[P]  
142 Washer  
143 Plate  
[SS]  
[C]  
[PS]  
[SY]  
[SS]  
[B]  
201 Muffler (see note 2)  
(1) 93107  
(8) 93095  
(1) 93339-1  
131 Bolt (5/16” - 18 x 1-1/4”)  
n 132 Gasket (see note 1)  
n
Key-Lube “O” Ring Lubricant  
10 Pack of Key-Lube  
93706-1  
637175  
Note1:Partno.93339-1one-piecegasketreplacesthefollowingparts(notshown)inmod-  
els manufactured prior to October 1988, Y325-10 (4), Y325-12, 93093, 93094,  
Y325-8.  
Note 2: The (129l) exhaust cover and (201) muffler were standard until 9/92. They are  
available separately for service or piped exhaust applications.  
Note 3: A major valve service assembly is available separately which includes items: 111,  
132, 135 - 141. Order part no. 66362.  
DIAPHRAGM PUMP SERVICE  
GENERAL SERVICE NOTES:  
S Inspect and replace old parts with new parts as necessary. Look for  
deep scratches on metallic surfaces, and nicks or cuts in “O” rings.  
S 7/16” wrench, 1/2” wrench, 7/16” socket, 1/2” socket, torque  
wrench (measuring inch pounds), “O” ring pick.  
MATERIAL CODE  
[B] = Nitrile  
[D] = Acetal  
[SY] = Syn-Seal  
[U] = Polyurethane  
[Z] = Zinc  
[Bz] = Bronze  
[P] = Polypropylene  
[PS] = Polyester  
[SS] = Stainless Steel  
FLUID SECTION DISASSEMBLY  
[C] = Carbon Steel  
[CK] = Ceramic  
1. Remove (34) top manifold / (36) swivel assembly.  
Note: Manifold options involve single piece manifolds (60 / 61) or three  
piece swivel type manifolds with clamps.  
2. Remove (41) ball cages, (22) balls, (19 and 20) “O” rings and (21)  
seats. Note: If cages are difficult to remove at this step, it may be  
helpful to proceed through step 5 and remove them once they are  
accessible from the inside of the fluid cap.  
3. Remove (35) bottom manifolds / (36) swivel assembly.  
4. Remove (19) “O” rings, (21) seats and (22) balls.  
5. Remove (15) fluid caps.  
6. Remove (6) diaphragm nut, (8) [(7) PTFE models only] dia-  
phragm(s) and (5) diaphragm washer from (1) diaphragm connect-  
ing rod.  
FLUID SECTION REASSEMBLY  
S Reassemble in reverse order.  
S Lubricate(1)connectingrodand(2)OringwithKey-Lubeorequiv-  
alent “O” ring lubricant.  
S Install (5) diaphragm washers with i.d. chamfer toward diaphragm.  
S WhenreplacingPTFEdiaphragms,installthe93465Santoprenedi-  
aphragm behind the PTFE diaphragm.  
S When installing (41) cage, ball guides must line up with notches in  
(21) seat to prevent damage.  
S Beforeinstalling(35),(34)manifolds,(19)Oringshouldbeproper-  
ly seated on the o.d. of (41) ball cage.  
S Before tightening (39) nut and (38) carriage bolts on (36) swivels,  
attach the manifold / swivel assembly to the fluid caps. Rotate (36)  
swiveltodesiredpositionandtighteneachofthenutsapproximately  
8 - 9 turns, then finish tightening (29) nuts.  
7. Remove (1) connecting rod from air motor.  
8. Carefully remove remaining (6) diaphragm nut, (8) [(7) PTFE mod-  
els] diaphragm and (5) diaphragm washer from (1) connecting rod.  
Do not mar surface of connecting rod.  
9. Remove (2) “O” ring from connecting rod.  
10. Remove (37) clamps from top and bottom manifold / swivel assem-  
blies.  
11. Remove (33) “O” rings from (36) swivels.  
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  
66605X-X (en)  
 
PARTS LIST / 66605X-X AIR MOTOR SECTION  
. TORQUE REQUIREMENTS ,  
NOTE: DO NOT OVERTIGHTEN FASTENERS.  
(134) Torque to 15 -20 in. lbs (1.7 -2.3 Nm), wait 10 minutes, then re-torque  
to 15 - 20 in. lbs (1.7 - 2.3 Nm).  
(OPTION) 129  
(see note 2, page 6)  
LUBRICATION / SEALANTS  
Apply Key-Lube (93706-1) to all “O” rings, “U” cups and mating parts.  
201 (OPTION)  
(seenote2,page6)  
131  
101  
103  
102  
133  
140  
141  
132  
MAJOR VALVE  
(see note 3, page 6)  
130  
129  
135  
143 104  
PILOT VALVE  
138  
. 134  
118  
142  
139  
137  
111  
119  
120  
119  
120 119  
120  
136  
119  
Figure 3  
142  
122  
AIR MOTOR SECTION SERVICE  
MAJOR VALVE DISASSEMBLY  
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.  
1. Remove (129) exhaust cover and (130) gasket.  
2. Pull (135) valve block assembly from (101) body.  
3. Remove (134) bolts, (133) washers and (132) gasket from (135)  
valve block.  
4. Remove (141) valve plate and (140) valve insert.  
5. Remove (136) plug and (111) spool.  
S Air Motor Section Service is continued from Fluid Section repair.  
PILOT VALVE DISASSEMBLY  
1. Remove (122) and (104) snap rings.  
2. Remove (143) plates.  
3. Remove (103) sleeve and (102) “O” rings.  
4. Remove (118) piston, (142) washers, (119) “O” rings and (120)  
spacers from (101) center body.  
MAJOR VALVE REASSEMBLY  
1. Install new (139) and (138) “U” cups on (111) spool -- LIPS MUST  
FACE EACH OTHER.  
2. Insert (111) spool into (135) valve block.  
3. Install(137)Oringon(136)plug, insertpluginto(135)valveblock.  
4. Install(140)valveinsertand(141)valveplateinto(135)valveblock.  
Note: After 9/92, parts (140, 141) are white (ceramic), the dished  
side of the (140) valve insert should be against the shiny face of  
(141) valve plate for best performance.  
5. Replace (132) gasket and install valve block assembly on (101)  
body.  
PILOT VALVE REASSEMBLY  
1. Assemble(119)Orings,(120)spacersand(142)washerson(118)  
pilot rod.  
2. Insertthestackintothe(101)body. Sleeve(103)maybeusedtoas-  
sist pressing stack into body.  
3. Install (103) sleeve and (102) “O” rings into (101) body.  
4. Install (143) plates and (122) and (104) snap rings.  
66605X-X (en)  
Page 7 of 8  
 
TROUBLE SHOOTING  
Product discharged from air exhaust.  
S Check for diaphragm rupture.  
S Check tightness of (6) diaphragm nut.  
Low output volume.  
S Check air supply.  
S Check for plugged outlet hose.  
S For the pump to prime itself, it must be mounted in the vertical posi-  
tion so that the balls will check by gravity.  
S Checkforpumpcavitation -- suctionpipeshouldbe1/2min. orlarg-  
er if high viscosity fluids are being pumped. Suction hose must be  
non-collapsible type, capable of pulling a high vacuum.  
S Checkalljointsonintakemanifoldsandsuctionconnections. These  
must be airtight.  
S Check for sticking or improperly seating check valves.  
S If pump cycles at a high rate or runs erratically, check (119) piston  
“O” rings for wear.  
Air Bubbles in Product Discharge.  
S Check connections of suction plumbing.  
S Check band clamps on intake manifold.  
S Check “O” rings between intake manifold and fluid caps.  
S Check tightness of (6) diaphragm nut.  
Pump blows air out main exhaust when stalled on either stroke.  
S Check “U” cups on (111) spool in major valve.  
S Check (141) valve plate and (140) insert for wear.  
S Check (103) sleeve and (2) “O” ring on diaphragm connecting rod.  
S Check (119) “O” rings on (118) piston for wear.  
DIMENSIONAL DATA  
Dimensions shown are for reference only, they are shown in inches and millimeters (mm).  
6-7/16”  
5-3/16”  
(164 mm)  
(132 mm)  
6”  
8-5/32”  
(152 mm)  
(207 mm)  
1/2 - 14 N.P.T.  
Material Outlet  
1/2 - 14 N.P.T.  
10-1/16”  
Air Inlet  
1/4 - 18 N.P.T.  
(255 mm)  
11-11/32”  
Material Inlet  
1/2 - 14 N.P.T.  
(288 mm)  
2-1/32”  
(51 mm)  
NOTE: LOOSENING THESE  
FASTENERS WILL ALLOW  
INLET / OUTLET TO ROTATE.  
5/16” Slot (8 mm)  
4-13/16”  
(122 mm)  
6-5/32” (156 mm)  
5-1/2”  
8-15/32” (215 mm)  
(140 mm)  
Single Piece Manifold  
Figure 4  
PN 97999-99  
66605X-X (en)  
Page 8 of 8  
 

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