OPERATOR’S MANUAL 66605X-X

INCLUDING: OPERATION, INSTALLATION & MAINTENANCE RELEASED: 4-15-87

REVISED: 1-23-12
(REV. AS)
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-Metallic Air Operated Double Diaphragm
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)
Maximum Outlet Pressure . . . . . . . . . . 100 p.s.i.g. (6.9 bar) 66605J-XXX 666053-XXX
66605H-XXX 666056-XXX
Air Consumption . . . . . . . . . . . . . . . . . 1 c.f.m. / gallon (approx.) 66605K-XXX 666057-XXX
Maximum Flow Rate (Ball) . . . . . . . 13 g.p.m. (49.2 l.p.m.) Figure 1
(Duckbill) . . . . 10 g.p.m. (37.9 l.p.m.)
Maximum Particle Size (Ball) . . . . . . . 3/32” dia. (2.4 mm) MODEL DESCRIPTION CHART
(Duckbill) . . . . Fibers
Maximum Temperature Limits 66605 X - X X X - 04
E.P.R. . . . . . . . . . . . . . . . . -60_ to 280_ F (-51_ to 138_ C) Fluid Caps & Manifold Material
Groundable Acetal . . . . . . . 10_ to 180_ F (-12_ to 82_ C) 3 - Piece Manifold Single Piece Manifold
HytrelR . . . . . . . . . . . . . . -20_ to 150_ F (-29_ to 66_ C) 3 - Polypropylene J - Polypropylene
Neoprene . . . . . . . . . . . . . 0_ to 200_ F (-18_ to 93_ C) 6 - Groundable Acetal H - Groundable Acetal
Nitrile . . . . . . . . . . . . . . . . 10_ to 180_ F (-12_ to 82_ C) 7 - Pure Kynar K - Pure Kynar
Polypropylene . . . . . . . . . . 35_ to 175_ F (2_ to 79_ C) Seat Material
Polyurethane . . . . . . . . . . . 10_ to 150_ F (-12_ to 66_ C) 0 - (Duck Bill) 4 - Kynar PVDF
Kynar PVDF . . . . . . . . . . . 10_ to 200_ F (-12_ to 93_ C) 2 - Stainless Steel 6 - Acetal
SantopreneR . . . . . . . . . . -40_ to 225_ F (-40_ to 107_ C) 3 - Polypropylene
PTFE . . . . . . . . . . . . . . . . 40_ to 225_ F (4_ to 107_ C)
Ball Material ( * ) Duckbill models
VitonR . . . . . . . . . . . . . . . -40_ to 350_ F (-40_ to 177_ C) 1 - Neoprene 8 - Polyurethane
Groundable . . . . . . . . . . . 666056-X and 66605H-X models only 2 - Nitrile A - Stainless Steel
Dimensional Data . . . . . . . . . . . . . . . . see page 8 3 - Viton C - Neoprene (*)
Noise Level @ 70 p.s.i., 60 c.p.m. . . . . . 71.1 db(A) 4 - PTFE D - Nitrile (*)
5 - E.P.R. E - Santoprene
* 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- Diaphragm Material
ROP S5.1 using four microphone locations. 1 - Neoprene 5 - E.P.R.
2 - Nitrile 8 - Polyurethane
NOTICE: All possible options are shown in the chart however certain com- 3 - Viton 9 - Hytrel
binations may not be recommended, consult a representative or the fac- 4 - PTFE / Santoprene B - Santoprene
tory if you have questions concerning availability.
Cone Check Flow
04 - Top Discharge
FLUID SECTION SERVICE KIT SELECTION 66605X - X X X
EXAMPLE: MODEL # 666053-321
Fluid Section Service Kit # 637140-21
637140 - X X
Ball Diaphragm

INGERSOLL RAND COMPANY LTD

209 NORTH MAIN STREET – BRYAN, OHIO 43506
(800) 495-0276 FAX(800) 892-6276 © 2012 CCN 99449712
www.ingersollrandproducts.com
 OPERATING AND SAFETY PRECAUTIONS
READ, UNDERSTAND AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.
WARNING HAZARDOUS MATERIALS. Can cause serious in-
EXCESSIVE AIR PRESSURE HAZARDOUS MATERIALS
STATIC SPARK HAZARDOUS PRESSURE jury 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
WARNING EXCESSIVE AIR PRESSURE. Can cause person- laws and safety code requirements.
al injury, pump damage or property damage. S Obtain Material Safety Data Sheets on all materials from the
S Do not exceed the maximum inlet air pressure as stated on the supplier for proper handling instructions.
pump model plate. CAUTION Verify the chemical compatibility of the pump
S Be sure material hoses and other components are able to with- wetted parts and the substance being pumped, flushed or re-
stand fluid pressures developed by this pump. Check all hoses circulated. Chemical compatibility may change with tempera-
for damage or wear. Be certain dispensing device is clean and ture and concentration of the chemical(s) within the
in proper working condition. substances being pumped, flushed or circulated. For specific
WARNING STATIC SPARK. Can cause explosion resulting in fluid compatibility, consult the chemical manufacturer.
severe injury or death. Ground pump and pumping system. CAUTION Maximum temperatures are based on mechani-
S Sparks can ignite flammable material and vapors. cal stress only. Certain chemicals will significantly reduce
S The pumping system and object being sprayed must be maximum safe operating temperature. Consult the chemical
grounded when it is pumping, flushing, recirculating or spray- manufacturer for chemical compatibility and temperature lim-
ing flammable materials such as paints, solvents, lacquers, its. Refer to Pump Data on page 1 of this manual.
etc. or used in a location where surrounding atmosphere is CAUTION Be certain all operators of this equipment have
conducive to spontaneous combustion. Ground the dispens- been trained for safe working practices, understand it’s limita-
ing valve or device, containers, hoses and any object to which tions, and wear safety goggles / equipment when required.
material is being pumped. CAUTION Do not use the pump for the structural support of
S 666056-XXX and 66605H-XXX Groundable Acetal pumps: Use
the pump grounding screw provided. Connect a 12 ga. (mini- the piping system. Be certain the system components are
mum) wire (kit is included) to a good earth ground source. properly supported to prevent stress on the pump parts.
S Secure pump, connections and all contact points to avoid S Suction and discharge connections should be flexible connec-
vibration and generation of contact or static spark. tions (such as hose), not rigid piped, and should be compatible
S Consult local building codes and electrical codes for specific with the substance being pumped.
grounding requirements. CAUTION Prevent unnecessary damage to the pump. Do
S After grounding, periodically verify continuity of electrical path not allow pump to operate when out of material for long periods
to ground. Test with an ohmmeter from each component (e.g., of time.
hoses, pump, clamps, container, spray gun, etc.) to ground to S Disconnect air line from pump when system sits idle for long
insure continuity. Ohmmeter should show 0.1 ohms or less. periods of time.
S Submerse the outlet hose end, dispensing valve or device in CAUTION Use only genuine ARO replacement parts to as-
the material being dispensed if possible. (Avoid free streaming sure compatible pressure rating and longest service life.
of material being dispensed.) NOTICE Install the pump in the vertical position. The
S Use hoses incorporating a static wire. pump may not prime properly if the balls do not check by gravi-
S Use proper ventilation. ty upon start-up.
S Keep inflammables away from heat, open flames and sparks.
S Keep containers closed when not in use. NOTICE Re-torque all fasteners before operation. Creep
of housing and gasket materials may cause fasteners to loos-
WARNING Pump exhaust may contain contaminants. Can
en. Re-torque all fasteners to insure against fluid or air leakage.
cause severe injury. Pipe exhaust away from work area and per-
sonnel. NOTICE Replacement warning labels are available upon
S In the event of a diaphragm rupture material can be forced out request: “Static Spark” pn \ 93616-1, “Diaphragm Rupture” pn \
of the air exhaust muffler. 93122.
S Pipe the exhaust to a safe remote location when pumping haz- WARNING = Hazards or unsafe practices which could
ardous or inflammable materials. result in severe personal injury, death or
S Use a grounded 3/8” minimum i.d. hose between the pump and substantial property damage.
the muffler.
WARNING HAZARDOUS PRESSURE. Can result in serious CAUTION = Hazards or unsafe practices which could
injury or property damage. Do not service or clean pump, result in minor personal injury, product
hoses or dispensing valve while the system is pressurized. or property damage.
S Disconnect air supply line and relieve pressure from the sys- NOTICE = Important installation, operation or
tem by opening dispensing valve or device and / or carefully maintenance information.
and slowly loosening and removing outlet hose or piping from
pump.

Page 2 of 8 66605X-X (en)

 GENERAL DESCRIPTION MAINTENANCE
The ARO diaphragm pump offers high volume delivery even at low air Refer to the part views and descriptions as provided on page 4 through 7
pressure and a broad range of material compatibility options available. for parts identification and Service Kit information.
Refer to the model and option chart. ARO pumps feature stall resistant S Certain ARO “Smart Parts” are indicated which should be available
design, modular air motor / fluid sections. for fast repair and reduction of down time.
Air operated double diaphragm pumps utilize a pressure differential in S Service kits are available to service two separate diaphragm pump
the air chambers to alternately create suction and positive fluid pressure functions: 1. AIR SECTION, 2. FLUID SECTION. The Fluid Section
in the fluid chambers. Ball checks insure a positive flow of fluid. is divided further to match typical active MATERIAL OPTIONS.
Pump cycling will begin as air pressure is applied and it will continue to S Provide a clean work surface to protect sensitive internal moving
pump and keep up with the demand. It will build and maintain line pres- parts from contamination from dirt and foreign matter during service
sure and will stop cycling once maximum line pressure is reached (dis- disassembly and reassembly.
pensing device closed) and will resume pumping as needed. S Keep good records of service activity and include pump in preven-
Models 666056-X and 66605H-X: The Acetal material used in these tive maintenance program.
pumps contains stainless steel fibers. It’s conductivity allows it to be con-
nected to a suitable ground. A ground screw and ground wire kit is pro- DUCKBILL CHECK VALVES (OPTIONAL)
vided for this.
Pump models with the suffix (-0CX or -0DX) come equipped with duckbill
AIR AND LUBE REQUIREMENTS type checks. Standard duckbill pumps are shipped with the material inlet
in the top and the material outlet on the bottom manifold. To change the
WARNING EXCESSIVE AIR PRESSURE. Can cause pump direction of flow, disassemble the pump as instructed in the FLUID SEC-
damage, personal injury or property damage. TION and reassemble as described below. A pump that was factory built
S A filter capable of filtering out particles larger than 50 microns should with balls and seats can be retro-fitted with duckbill type check valves by
be used on the air supply. There is no lubrication required other than purchasing the necessary parts and installing them as shown.
the “O” ring lubricant which is applied during assembly or repair. Reassembly:
S If lubricated air is present, make sure that it is compatible with the “O” The duckbills may be installed in either direction to produce flow from top
rings and seals in the air motor section of the pump. 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)
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)
S Always flush the pump with a solvent compatible with the material duckbill.
being pumped if the material being pumped is subject to “setting up” 3. Slide the complete check assembly into the fluid cap bore with the
when not in use for a period of time. (21) insert end first. [Duckbills (42) point up.]
S Disconnect the air supply from the pump if it is to be inactive for a few 4. Position (19) “O” ring over (41) sleeve.
hours. 5. Attach (35) manifold feet / (36) swivel assembly to the fluid caps.
S The outlet material volume is governed not only by the air supply but 6. Turn pump over to right side up position.
also by the material supply available at the inlet. The material supply 7. Assemble duckbill check as in step #1.
tubing should not be too small or restrictive. Be sure not to use hose 8. Slide the complete check assembly into the fluid cap bore with the
which might collapse. (41) sleeve end first. [Duckbill is pointing down toward fluid cap cav-
S When the diaphragm pump is used in a forced-feed (flooded inlet) ity.]
situation, it is recommended that a “Check Valve” be installed at the 9. Position (19) “O” ring around (21) insert.
air inlet. 10. Attach (34) manifold / (36) swivel assembly to fluid cap.
S Secure the diaphragm pump legs to a suitable surface to insure Flow from Bottom to Top: (Inlet Bottom - Outlet Top)
against damage by vibration. To reverse flow direction, slide check valve assemblies into the (15) fluid
caps backwards from what is indicated in steps #2 and #7. In step #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 BALL OPTIONS MATERIAL CODE
ITEM “21” ITEM “22” (3/4” dia.) (Service Kit -XX) [B] = Nitrile
[D] = Acetal
-XXX Seat Qty [Mtl] -XXX Ball Qty [Mtl] -XXX Ball Qty [Mtl] [E] = E.P.R.
-2XX 93409-1 (4) [SS] -X1X 93100-1 (4) [N] -XAX 93410-1 (4) [SS] [F] = Fluoraz
[GA] = Groundable Acetal
-3XX 93098-1 (4) [P] -X2X 93100-2 (4) [B] -XEX 93100-E (4) [Sp] [GFN] =Glass Filled Nylon
-34X / -3AX 93098-10 (4) [P] -X3X 93100-3 (4) [V] [H] = Hytrel
[N] = Neoprene
-4XX 93098-4 (4) [PK] -X4X 93100-4 (4) [T] -0XX ITEM “42” (Duckbill) [P] = Polypropylene
-6XX 93098-3 (4) [D] [PK] = Pure Kynar
-X5X 93100-5 (4) [E] -0CX 93114-1 (4) [N]
[Sp] = Santoprene
-0XX 93115-1 (4) [P] -X8X 93100-8 (4) [U] -0DX 93114-2 (4) [B] [SS] = Stainless Steel
[T] = PTFE
[U] = Polyurethane
DIAPHRAGM OPTIONS [V] = Viton
l Service Kits “7” / “8” “19” “20” “33” K
-XX = (Ball or Duckbill) “O” Ring (4) “O” Ring (2) “O” Ring (4)
66605X-XXX -XX = (Diaphragm) Diaphragm (2) [Mtl] 1-5/16” o.d. 1-1/8” o.d. 1-3/16” o.d. [Mtl]
-XX1 637140-X1 93113 [N] Y325-122 Y325-119 Y325-120 [B]
-XX2 637140-X2 93465-G [B] Y325-122 Y325-119 Y325-120 [B]
-XX3 637140-X3 93581-3 [V] Y327-122 Y327-119 Y327-120 [V]
H Not shown
666053-, 66605J-XX4 637140-X4 93111 / 93465 [T/Sp] 93265 Y328-119 94749 [T]
666056-, 66605H-XX4 637140-X4 93111 / 93465 [T/Sp] 93764 93933 95129 [F] s Quantity = 22
666057-, 66605K-XX4 637140-X4 93111 / 93465 [T/Sp] 93265 Y328-119 94749 [T]
-XX5 637140-X5 93760 [E] 93763 93761 93762 [E]
-XX8 637140-X8 93112 [U] 93119 93117 93118 [U]
-XX9 637140-X9 93465-9 [H] Y325-122 Y325-119 Y325-120 [B]
-XXB 637140-XB 93465 [Sp] 93763 93761 93762 [E]
-0X1 637140-C1, D1 93113 [N] Y325-122 Not Req’d Y325-120 [B]
-0X2 637140-C2, D2 93465-G [B] Y325-122 Not Req’d Y325-120 [B]
-0X4 637140-C4, D4 93111 / 93465 [T/Sp] Y325-122 Not Req’d 94749 [T]
-0X8 637140-C8, D8 93112 [U] 93119 Not Req’d 93118 [U]
-0XB 637140-CB, DB 93465 [Sp] Y325-122 Not Req’d Y325-120 [B]
K Item “33” “O” rings are not used on models 66605H-XXX, 66605J-XXX and 66605K-XXX.
WETTED COMMON PARTS
Polypropylene Groundable Acetal Pure Kynar
666053-XXX 66605J-XXX 666056-XXX 66605H-XXX 666057-XXX 66605K-XXX
Item Description (size) Qty Part No. Mtl Part No. Mtl Part No. Mtl Part No. Mtl Part No. Mtl Part No. Mtl
V 1 Rod (1) 93084 [SS] 93084 [SS] 93084 [SS] 93084 [SS] 93084 [SS] 93084 [SS]
2 “O” Ring (3/32” x 5/8” o.d.) (1) Y325-111 [B] Y325-111 [B] Y325-111 [B] Y325-111 [B] Y325-111 [B] Y325-111 [B]
5 Washer (2” o.d.) (2) 94645 [GFN] 94645 [GFN] 94645 [GFN] 94645 [GFN] 94645 [GFN] 94645 [GFN]
V 6 Diaphragm Nut (5/16” - 18) (2) 93103-1 [P] 93103-1 [P] 93103-3 [D] 93103-3 [D] 93103-4 [PK] 93103-4 [PK]
15 Fluid Cap (includes 26 & 124) (2) 93105-1 [P] 93105-1 [P] 93105-11 [GA] 93105-11 [GA] 93105-9 [PK] 93105-9 [PK]
26 Bolt (5/16” - 18 x 1-1/2”) (8) 93109 [SS] 93109 [SS] 93109 [SS] 93109 [SS] 93109 [SS] 93109 [SS]
29 Nut (5/16” - 18) (2) ----- --- ----- --- Y12-5-S [SS] Y12-5-S [SS] ----- --- ----- ---
34 Manifold, Outlet (top) (2) 93102-1 [P] ----- --- 93102-6 [GA] ----- --- 93102-4 [PK] ----- ---
V 35 Manifold, Foot (bottom) (2) 93106-1 [P] ----- --- 93106-6 [GA] ----- --- 93106-4 [PK] ----- ---
V 36 Swivel (2) 93101-1 [P] ----- --- 93101-6 [GA] ----- --- 93101-4 [PK] ----- ---
V 37 Clamp (8) 93099 [SS] ----- --- 93099 [SS] ----- --- 93099 [SS] ----- ---
38 Bolt (#10 - 24 x 1-1/2”) (8) Y84-303-T [SS] ----- --- Y84-303-T [SS] ----- --- Y84-303-T [SS] ----- ---
39 Nut (#10 - 24) (8) Y22-10-S [SS] ----- --- Y22-10-S [SS] ----- --- Y22-10-S [SS] ----- ---
41a Ball Cage (4) 93097-1 [P] 93097-1 [P] 93097-3 [D] 93097-3 [D] 93097-4 [PK] 93097-4 [PK]
41b Sleeve (models 66605X-0XX) (4) 93120-1 [P] 93120-1 [P] ----- --- ----- --- ----- --- ----- ---
43 Ground Strap (1) ----- --- ----- --- 92956-1 [SS] 92956-1 [SS] ----- --- ----- ---
H 57 Ground Kit Assembly (1) ----- --- ----- --- 66885-1 --- 66885-1 --- ----- --- ----- ---
60 Manifold, Inlet (bottom) (1) ----- --- 93802-1 [P] ----- --- 93802-2 [GA] ----- --- 93802-3 [PK]
61 Manifold, Outlet (top) (1) ----- --- 93801-1 [P] ----- --- 93801-2 [GA] ----- --- 93801-3 [PK]
62 Flange Nut (5/16” - 18) (24) 93886 [SS] 93886 [SS] 93886 (s) [SS] 93886 (s) [SS] 93886 [SS] 93886 [SS]
63 Plug (1/2 - 14 N.P.T.) (6) - - - - - --- 93897-1 [P] ----- --- 93897-2 [D] ----- --- 93897-3 [PK]
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 Ball
Material Color Color
61 Acetal N/A Orange
Nitrile Red (--) Red (S)
63 , E.P.R. Blue (--) Blue (S)
OUTLET Hytrel Cream N/A
Neoprene Green (--) Green (S)
66605X-0XX-04 Santoprene Tan Tan
PTFE White White
Polyurethane Clear Red

FLOW
Viton Yellow (--) Yellow (S)

FLOW
38 (--) Stripe (S) Dot

37 FOR THE
19 19 AIR MOTOR SECTION
36 SEE PAGES 6 & 7
21
. 62 33 41b
34
42 k 42
. 39 19

41a
41b 21
OUTLET 22

20

21
124
26

15

62 ,

2 1

29 ,
5 8
43

7Y 6,
26

21 41b
k 42 41a
FLOW

42 36 33
FLOW

22
41b
21 21
19 19 19
66605X-0XX-04 35

k When duckbills face down, the inlet is on the top.

Y Used on 66605X-XX4 (PTFE) models only.
INLET
. 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 60
and evenly, then re-torque after initial run-in.
(39) Nuts, 20 - 25 in. lbs (2.3 - 2.8 Nm) then re-torque. 63 ,
(63) Plugs, 25 in. lbs (2.8 Nm) maximum.

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) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]
101 Motor Body (1) 93091 [P] 133 Washer (9/32” i.d.) (4) 93096 [SS]
n 102 “O” Ring (3/32” x 1” o.d.) (2) Y325-117 [B] 134 Bolt (1/4” - 20 x 5”) (4) Y6-419-T [SS]
j 103 Sleeve (1) 93087 [Bz] 135 Valve Block (1) 93090 [P]
j 104 Snap Ring (13/16”) (2) 37285 [C] 136 Plug (1) 93086 [D]
111 Spool (1) 93085 [D] n 137 “O” Ring (3/32” x 1-1/2” o.d.) (1) Y325-125 [B]
118 Pilot Rod (1) 93088 [C] n 138 Packing, “U” Cup (1/8” x 1” o.d.) (1) 94395 [U]
n 119 “O” Ring (1/8” x 3/4” o.d.) (4) 93075 [U] n 139 Packing, “U” Cup (1/8” x 1.427” o.d.) (1) 96383 [U]
j 120 Spacer (3) 115959 [Z] n 140 Valve Insert (1) 93276 [CK]
n 122 Snap Ring (1/2”) (2) 77802 [C] n 141 Valve Plate (1) 93275 [CK]
124 Stud (5/16” - 18 x 1-17/32”) (see page 5) (8) 93249 [SS] 142 Washer (2) 116038 [Z]
129 Muffler Assembly (1) 66972 [P] 143 Plate (2) 93089 [SS]
129l Exhaust Cover (see note 2) 93092 [PS] 201 Muffler (see note 2) 93110 [C]
n 130 Gasket (1) 93107 [SY]
131 Bolt (5/16” - 18 x 1-1/4”) (8) 93095 [SS] n Key-Lube “O” Ring Lubricant 93706-1
n 132 Gasket (see note 1) (1) 93339-1 [B] 10 Pack of Key-Lube 637175

Note 1: Part no.93339-1 one-piece gasket replaces the following parts (not shown) in mod-
DIAPHRAGM PUMP SERVICE els manufactured prior to October 1988, Y325-10 (4), Y325-12, 93093, 93094,
Y325-8.
GENERAL SERVICE NOTES: Note 2: The (129l) exhaust cover and (201) muffler were standard until 9/92. They are
S Inspect and replace old parts with new parts as necessary. Look for available separately for service or piped exhaust applications.
deep scratches on metallic surfaces, and nicks or cuts in “O” rings. Note 3: A major valve service assembly is available separately which includes items: 111,
132, 135 - 141. Order part no. 66362.
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
FLUID SECTION DISASSEMBLY [Bz] = Bronze [P] = Polypropylene [U] = Polyurethane
[C] = Carbon Steel [PS] = Polyester [Z] = Zinc
[CK] = Ceramic [SS] = Stainless Steel
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. FLUID SECTION REASSEMBLY
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 S Reassemble in reverse order.
helpful to proceed through step 5 and remove them once they are S Lubricate (1) connecting rod and (2) “O” ring with Key-Lube or equiv-
accessible from the inside of the fluid cap. alent “O” ring lubricant.
3. Remove (35) bottom manifolds / (36) swivel assembly. S Install (5) diaphragm washers with i.d. chamfer toward diaphragm.
4. Remove (19) “O” rings, (21) seats and (22) balls. S When replacing PTFE diaphragms, install the 93465 Santoprene di-
5. Remove (15) fluid caps. aphragm behind the PTFE diaphragm.
6. Remove (6) diaphragm nut, (8) [(7) PTFE models only] dia- S When installing (41) cage, ball guides must line up with notches in
phragm(s) and (5) diaphragm washer from (1) diaphragm connect- (21) seat to prevent damage.
ing rod. S Before installing (35), (34) manifolds, (19) “O” ring should be proper-
7. Remove (1) connecting rod from air motor. ly seated on the o.d. of (41) ball cage.
8. Carefully remove remaining (6) diaphragm nut, (8) [(7) PTFE mod- S Before tightening (39) nut and (38) carriage bolts on (36) swivels,
els] diaphragm and (5) diaphragm washer from (1) connecting rod. attach the manifold / swivel assembly to the fluid caps. Rotate (36)
Do not mar surface of connecting rod. swivel to desired position and tighten each of the nuts approximately
9. Remove (2) “O” ring from connecting rod. 8 - 9 turns, then finish tightening (29) nuts.
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
LUBRICATION / SEALANTS (see note 2, page 6)
Apply Key-Lube (93706-1) to all “O” rings, “U” cups and mating parts.

201 (OPTION)
131 101 103 102 (see note 2, page 6)

133 140 141 132

MAJOR VALVE
(see note 3, page 6)

130 129

135

143 104
138
PILOT VALVE
. 134

118
139 142
111 119
120 119
137 120 119
120
136 Figure 3 119 142 122

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.
S Air Motor Section Service is continued from Fluid Section repair. 2. Pull (135) valve block assembly from (101) body.
3. Remove (134) bolts, (133) washers and (132) gasket from (135)
valve block.
PILOT VALVE DISASSEMBLY 4. Remove (141) valve plate and (140) valve insert.
1. Remove (122) and (104) snap rings. 5. Remove (136) plug and (111) spool.
2. Remove (143) plates.
3. Remove (103) sleeve and (102) “O” rings. MAJOR VALVE REASSEMBLY
4. Remove (118) piston, (142) washers, (119) “O” rings and (120)
spacers from (101) center body. 1. Install new (139) and (138) “U” cups on (111) spool -- LIPS MUST
FACE EACH OTHER.
2. Insert (111) spool into (135) valve block.
PILOT VALVE REASSEMBLY 3. Install (137) “O” ring on (136) plug, insert plug into (135) valve block.
1. Assemble (119) “O” rings, (120) spacers and (142) washers on (118) 4. Install (140) valve insert and (141) valve plate into (135) valve block.
pilot rod. Note: After 9/92, parts (140, 141) are white (ceramic), the dished
2. Insert the stack into the (101) body. Sleeve (103) may be used to as- side of the (140) valve insert should be against the shiny face of
sist pressing stack into body. (141) valve plate for best performance.
3. Install (103) sleeve and (102) “O” rings into (101) body. 5. Replace (132) gasket and install valve block assembly on (101)
4. Install (143) plates and (122) and (104) snap rings. body.

66605X-X (en) Page 7 of 8

 TROUBLE SHOOTING
Product discharged from air exhaust. Low output volume.
S Check for diaphragm rupture. S Check air supply.
S Check tightness of (6) diaphragm nut. S Check for plugged outlet hose.
S For the pump to prime itself, it must be mounted in the vertical posi-
Air Bubbles in Product Discharge. tion so that the balls will check by gravity.
S Check connections of suction plumbing. S Check for pump cavitation -- suction pipe should be 1/2” min. or larg-
S Check band clamps on intake manifold. er if high viscosity fluids are being pumped. Suction hose must be
S Check “O” rings between intake manifold and fluid caps. non-collapsible type, capable of pulling a high vacuum.
S Check tightness of (6) diaphragm nut. S Check all joints on intake manifolds and suction connections. These
must be airtight.
Pump blows air out main exhaust when stalled on either stroke. S Check for sticking or improperly seating check valves.
S Check “U” cups on (111) spool in major valve. S If pump cycles at a high rate or runs erratically, check (119) piston
S Check (141) valve plate and (140) insert for wear. “O” rings 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).

1/2 - 14 N.P.T Material Outlet

E
A F

L
M
B

K G 1/4 - 18 N.P.T Air Inlet NOTE: Loosening these

C fasteners will allow Inlet /
J H Outlet to rotate

1/2 - 14 N.P.T
Material Inlet

Figure 4

DIMENSIONS
A - 8.155” (207.1 mm) E - 6.467” (164 mm) J - 8.445” (215 mm)
B - 10.051” (255 mm) F - 6.000” (152 mm) K - 0.312” (8 mm)
C - 6.135” (155.8 mm) G - 4.812” (122.2 mm) L - 11.331” (288 mm)
D - 2.005” (51 mm) H - 5.500” (140 mm) M - 11.084” (282 mm)
N - 6.040” (153 mm)

PN 97999-99
Page 8 of 8 66605X-X (en)