Ingersoll-Rand PD05P-XXX-XXX-B - Manual (Page 6)

Page 6 of 8 PD05P-XXX-XXX-B (en)
Items included in fl uid section service kit, see page 4.
MATERIAL CODE
[B] = Nitrile [PPG] = Glass fi lled Polypropylene
[C] = Carbon Steel [SS] = Stainless Steel
[Ck] = Ceramic [Sy] = Syn-Seal
[D] = Acetal [U] = Polyurethane
DIAPHRAGM PUMP SERVICE
GENERAL SERVICE NOTES:
Inspect and replace old parts with new parts as necessary. Look
for deep scratches on metallic surfaces, and nicks or cuts in “O”
rings.
Tools needed to complete disassembly and repair:
7/8” socket or wrench, 1/2” socket or wrench, 3/8” socket
or wrench, 3/8” Allen wrench, T-10 Torx screwdriver, torque
wrench (measuring inch pounds), “O” ring pick.
FLUID SECTION DISASSEMBLY
Remove (61) top manifold.
Remove (19) “O” rings, (21) seats and (22) balls.
Remove (60) bottom manifold.
Remove (19) “O” rings, (21) seats and (22) balls.
Remove (15) fl uid caps.
Remove (6) diaphragm nut, (7) or (7 / 8) diaphragms and (5)
washer.
Remove (1) connecting rod from air motor.
Carefully remove remaining (6) diaphragm nut, (7) or (7 / 8) dia-
phragms and (5) washer from (1) connecting rod. Do not mar
surface of connecting rod.
FLUID SECTION REASSEMBLY
Reassemble in reverse order.
Lubricate (1) connecting rod with Lubriplate or equivalent “O”
ring lubricant.
Connecting rod (1) should be installed using 96571 bullet, in-
cluded in service kit.
1.
2.
3.
4.
5.
6.
7.
8.
Install (5) washers with i.d. chamfer toward diaphragm.
When replacing Teflon diaphragms, install the 93465 Santo-
prene diaphragm behind the Tefl on diaphragm.
AIR MOTOR SECTION SERVICE
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.
Air Motor Section service is continued from Fluid Section repair.
PILOT VALVE DISASSEMBLY
Remove (123) screws, releasing (103) covers, (121) washers,
(118) actuator pins and (167) pilot piston.
Remove (170) spool bushing and inspect inner bore of bushing
for damage.
PILOT VALVE REASSEMBLY
Clean and lubricate parts not being replaced from service kit.
Assemble (171) “O” rings to (170) bushing and assemble bush-
ing into (101) center body.
Lubricate and assemble (167) pilot piston assembly into (170)
bushing.
Assemble (173 and 174) “O” rings and (121) washers to (103)
covers, then insert (118) actuator pins through assembly.
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).
MAJOR VALVE DISASSEMBLY
Unthread (134) bolts, releasing (129) muffl er assembly.
Pull (135) valve block and components from (101) center body.
Remove (132) gasket, (141) valve plate and (140) valve insert
from (135) valve block.
Remove (134) bolts, releasing (107 and 136) plugs and (111)
spool.
1.
2.
1.
2.
3.
4.
5.
1.
2.
3.
4.
PARTS LIST / PD05P-XXX-XXX-B AIR MOTOR SECTION
AIR MOTOR PARTS LIST
Item Description (size) Qty Part No. Mtl
101 Center Body (1) 96315 [PPG]
103R Cover (right side) (1) 96091 [D]
103L Cover (left side) (1) 96351 [D]
107 Plug, Small (1) 96353 [D]
111 Major Valve Spool (1) 95919 [D]
118 Actuator Pin (2) 97111 [SS]
121 Washer (2) 96092 [D]
123 Screw (#4 - 20 x 1/2”) (8) 96093 [SS]
129 Muffl er Assembly (1) 67367 [PPG]
129 Exhaust Cover (optional) (1) 67366 [PPG]
130 Gasket (optional) (1) 93107 [Sy]
132 Air Manifold Gasket (1) 96214-1 [B]
134 Flange Bolt (1/4” - 20 x 5-3/4”) (4) 94871 [SS]
135 Valve Block (1) 96204 [PPG]
136 Plug, Large (1) 96352 [D]
137 “O” Ring (1/16” x 1-5/8” o.d.) (3) Y325-29 [B]
138 “U” Cup Packing (1/8” x 1” o.d.) (1) 94395 [U]
139 “U” Cup Packing (1/8” x 1-7/16” o.d.) (1) 96383 [U]
Item Description (size) Qty Part No. Mtl
140 Valve Insert (1) 93276 (Ck)
141 Valve Plate (1) 96173 (Ck)
144 “U” Cup Packing (3/16” x 1” o.d.) (2) Y187-48 [B]
166 “O” Ring (1/16” x 1-1/4” o.d.) (1) Y325-24 [B]
167 Pilot Piston (includes 168 and 169) (1) 67382 [D]
168 "O” Ring (1/16” x 7/16” o.d.) (2) 96459 [U]
169 “U” Cup Packing (1/8” x 5/8” o.d.) (1) 96384 [U]
170 Spool Bushing (1) 96090 [D]
171 “O” Ring (1/16” x 13/16” o.d.) (2) Y325-17 [B]
173 “O” Ring (3/32” x 7/8” o.d.) (2) Y325-115 [B]
174 “O” Ring (3/32” x 11/32” o.d.) (2) Y325-105 [B]
200 Porting Gasket (1) 96364 [B]
201 Muffl er (optional) (1) 93110 [C]
232 “O” Ring (1/16” x 3/8” o.d.) (optional) (4) Y325-10 [B]
Ported Exhaust Kit (includes items
129, 130 and 232) (optional)
(1) 637438 - - -
Lubriplate FML-2 grease (1) 94276
Lubriplate Grease Packets (10) 637308
Indicates parts included in 637428 air section service kit.