Ingersoll Rand 66615X X C Users Manual 66615X_X_C_Y_

66615X-X-C to the manual b9180858-cd21-4249-b491-59cf0601e549

2015-01-23

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E2010 CCN 81660219
(800) 276-4658 DFAX (800) 266-7016
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET -- BRYAN, OHIO 43506
OPERATOR’S MANUAL 66615X-X-C
RELEASED: 5-31-88
REVISED: 12-1-10
(REV. AB)
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
1-1/2” 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 the Model Description Chart to match the pump material op-
tions.
637118-C for air section repair (see page 6).
637124-XX for fluid section repair (see page 4).
637155 Abrasion Resistant Conversion Kit is available for use in heavy
and abrasive material applications (see page 4).
PUMP DATA
Models see “Model Description Chart” for “-XXX”............
Pump Type Metallic Air Operated Double Diaphragm.........
Material see “Model Description Chart”............
Weight Aluminum 51.54 lbs (23.4 kgs).... ...........
Cast Iron 79.54 lbs (36.1 kgs)............
Stainless Steel 84.54 lbs (38.3 kgs)........
[add 23 lbs (10.4 kgs) for cast iron air motor section]
Maximum Air Inlet Pressure 120 p.s.i. (8.3 bar)........
Maximum Material Inlet Pressure 10 p.s.i. (0.69 bar)....
Maximum Outlet Pressure 120 p.s.i. (8.3 bar).........
Maximum Flow Rate (flooded inlet) 90 g.p.m. (340.7 l.p.m.)....
Displacement / Cycle @ 100 p.s.i.g. 0.64 gal. (2.42 lit.)..
Maximum Particle Size 1/4” dia. (6.4 mm)...........
Maximum Temperature Limits (diaphragm / ball / seat material)
Acetal 10_to 180_F(-12_to 82_C).................
E.P.R. -60_to 280_F(-51_to 138_C).................
HytrelR-20_to 150_F(-29_to 66_C)...............
KynarRPVDF 10_to 200_F(-12_to 93_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)............
PTFE 40_to 225_F(4_to 107_C).................
SantopreneR-40_to 225_F(-40_to 107_C)...........
VitonR-40_to 350_F(-40_to 177_C)................
Dimensional Data see page 8...............
Noise Level @ 70 p.s.i. - 60 c.p.m.77.7 dba(A)..
Tested with 93139 muffler assembly installed.
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.
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.
66615X-XXX-C
1-1/2” DIAPHRAGM PUMP Figure 1
MODEL DESCRIPTION CHART
6661 X X-XX X -C
6661XX - X X X-C
637124 - X X
DiaphragmBall
FLUID SECTION SERVICE KIT SELECTION
EXAMPLE: MODEL # 666150-361-C
FLUID SECTION SERVICE KIT # 637124-61
Seat Material
1 - Aluminum 4 - Kynar PVDF
2 - 316 Stainless Steel 5 - Carbon Steel
3 - Polypropylene 8 - 440 Stainless Steel
Diaphragm Material
1 - Neoprene 5 - E.P.R.
2 - Nitrile 9 - Hytrel
3 - Viton B - Santoprene
4 - PTFE / Santoprene
Center Body Material, Threads
5 - Aluminum, N.P.T.F. 7 - Aluminum, BSP
6 - Cast Iron, N.P.T.F. 8 - Cast Iron, BSP
Fluid Cap / Manifold Material, Hardware
(Steel Hardware) (Stainless Steel Hardware)
0 - Aluminum A - Aluminum
1 - Stainless Steel B - Stainless Steel
2 - Cast Iron C - Cast Iron
Ball Material
1 - Neoprene 6 - Acetal
2 - Nitrile 8 - Polyurethane
3 - Viton A - Stainless Steel
4 - PTFE C - Hytrel
5 - E.P.R. E - Santoprene
www.ingersollrandproducts.com
66615X-X-C (en)Page 2 of 8
OPERATING AND SAFETY PRECAUTIONS
READ, UNDERSTAND AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.
EXCESSIVE AIR PRESSURE
STATIC SPARK
HAZARDOUS MATERIALS
HAZARDOUS PRESSURE
WARNING EXCESSIVE AIR PRESSURE. Can cause person-
al injury, pump damage or property damage.
SDo not exceed the maximum inlet air pressure as stated on the
pump model plate.
SBe sure material hoses and other components are able to with-
stand fluid pressures developed by this pump. Check all hoses
for damage or wear. Be certain dispensing device is clean and
in proper working condition.
WARNING STATIC SPARK. Can cause explosion resulting in
severe injury or death. Ground pump and pumping system.
SSparks can ignite flammable material and vapors.
SThe pumping system and object being sprayed must be
grounded when it is pumping, flushing, recirculating or spray-
ing flammable materials such as paints, solvents, lacquers,
etc. or used in a location where surrounding atmosphere is
conducive to spontaneous combustion. Ground the dispens-
ing valve or device, containers, hoses and any object to which
material is being pumped.
SUse the pump grounding screw terminal provided. Use ARO
R
part no. 66885-1 ground kit or connect a suitable ground wire
(12 ga. minimum) to a good earth ground source.
SSecure pump, connections and all contact points to avoid
vibration and generation of contact or static spark.
SConsult local building codes and electrical codes for specific
grounding requirements.
SAftergrounding,periodicallyverifycontinuityof electrical path
to ground. Test with an ohmmeter from each component (e.g.,
hoses, pump, clamps, container, spray gun, etc.) to ground to
insure continuity. Ohmmeter should show 0.1 ohms or less.
SSubmerse the outlet hose end, dispensing valve or device in
the material being dispensed if possible. (Avoid free streaming
of material being dispensed.)
SUse hoses incorporating a static wire.
SUse proper ventilation.
SKeep inflammables away from heat, open flames and sparks.
SKeep containers closed when not in use.
WARNING Pump exhaust may contain contaminants. Can
causesevere injury.Pipeexhaust away from workareaandper-
sonnel.
SIn the event of a diaphragm rupture, material can be forced out
of the air exhaust muffler.
SPipe the exhaust to a safe remote location when pumping haz-
ardous or inflammable materials.
SUse a grounded 3/4” minimum i.d. hose between the pump and
the muffler.
WARNING HAZARDOUS PRESSURE. Can result in serious
injury or property damage. Do not service or clean pump,
hoses or dispensing valve while the system is pressurized.
SDisconnect air supply line and relieve pressure from the sys-
tem by opening dispensing valve or device and / or carefully
and slowly loosening and removing outlet hose or piping from
pump.
WARNING HAZARDOUS MATERIALS. Can causeseriousin-
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
laws and safety code requirements.
SObtain Material Safety Data Sheets on all materials from the
supplier for proper handling instructions.
WARNING EXPLOSION HAZARD. Models containing alumi-
num wetted parts cannot be used with 1,1,1-trichloroethane,
methylene chloride or other halogenated hydrocarbon sol-
vents which may react and explode.
SCheck pump motor section, fluid caps, manifolds and all
wetted parts to assure compatibility before using withsolvents
of this type.
CAUTION Verify the chemical compatibility of the pump
wetted parts and the substance being pumped, flushed or re-
circulated. Chemical compatibility may change with tempera-
ture and concentration of the chemical(s) within the
substances being pumped, flushed or circulated. For specific
fluid compatibility, consult the chemical manufacturer.
CAUTION Maximum temperatures are based on mechani-
cal stress only. Certain chemicals will significantly reduce
maximum safe operating temperature. Consult the chemical
manufacturer for chemical compatibility and temperature lim-
its.RefertoPUMPDATAonpage1ofthismanual.
CAUTION Be certain all operators of this equipment have
been trained for safe working practices, understand it’s limita-
tions and wear safety goggles / equipment when required.
CAUTION Do not use the pump for the structural support of
the piping system. Be certain the system components are
properly supported to prevent stress on the pump parts.
SSuction and discharge connections should be flexible connec-
tions (such as hose), not rigid piped, and should be compatible
with the substance being pumped.
CAUTION Prevent unnecessary damage to the pump. Do
not allow pump to operate when out of materialfor long periods
of time.
SDisconnect air line from pump when system sits idle for long
periods of time.
CAUTION Use only genuine ARO replacement parts to as-
sure compatible pressure rating and longest service life.
NOTICE Replacement warning labels are available upon
request: “Static Spark” (93616-1) & “Diaphragm Rupture”
(93122).
WARNING
CAUTION
NOTICE
= Hazards or unsafe practices which could
result in severe personal injury, death or
substantial property damage.
= Hazards or unsafe practices which could
result in minor personal injury, product or
property damage.
= Important installation, operation or
maintenance information.
Page 3 of 866615X-X-C (en)
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 differential in
the air chambers to alternately create suction and positive fluid pressure
in the fluid chambers, valve 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.
AIR AND LUBE REQUIREMENTS
WARNING EXCESSIVE AIR PRESSURE. Can cause pump
damage, personal injury or property damage.
SA filter capable of filtering out particles larger than 50 microns should
be used on the air supply. There is no lubrication required other than
the “O” ring lubricant which is applied during assembly or repair.
SIf 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
SAlways flush the pump with a solvent compatible with the material
being pumped if the material being pumped is subject to “setting up”
when not in use for a period of time.
SDisconnect the air supply from the pump if it is to be inactive for a few
hours.
SThe 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 collapse.
SWhen 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.
SSecure the diaphragm pump legs to a suitable surface to insure
against damage by vibration.
MAINTENANCE
Refer to the part views and descriptions as provided on pages 4through
7 for parts identification and service kit information.
SCertain ARO “Smart Parts” are indicated which should be available
for fast repair and reduction of down time.
SService kits are divided to service two separate diaphragm pump
functions: 1. AIR SECTION, 2. FLUID SECTION. The FLUID SEC-
TION is divided further to match typical part MATERIAL OPTIONS.
SProvide a clean work surface to protect sensitive internal moving
parts from contamination from dirt and foreign matter during service
disassembly and reassembly.
SKeep good records of service activity and include pump in preven-
tive maintenance program.
SBefore disassembling, empty captured material in the outlet man-
ifold by turning the pump upside down to drain material from the
pump.
FLUID SECTION DISASSEMBLY
1. Remove top manifold(s).
2. Remove (22) balls, (19) “O” rings and (21) seats.
3. Remove (15) fluid caps.
NOTE: Only PTFE diaphragm models use a primary diaphragm (7) and
a backup diaphragm (8). Refer to the auxiliary view in the Fluid Section
illustration.
4. Remove the (14) screws, (6) washers, (7) or (7 / 8) diaphragms and
(5) washers.
5. Remove (3) “O” rings.
NOTE: Do not scratch or mar the surface of (1) diaphragm rod.
FLUID SECTION REASSEMBLY
SReassemble in reverse order.
SClean and inspect all parts. Replace worn or damaged parts with
new parts as required.
SLubricate (1) diaphragm rod and (2) “O” ring with Key-Lube “O” ring
lube.
SUse ARO pn / 98931-T bullet (installation tool) to aid in installation of
(2) “O” ring on (1) diaphragm rod.
SBe certain (7) or (7 / 8) diaphragm(s) align properly with (15) fluid
caps before making final torque adjustments on bolt and nuts to
avoid twisting the diaphragm.
SFor models with PTFE diaphragms: Item (8) Santoprenediaphragm
is installed with the side marked “AIR SIDE” towards the pump cen-
ter body. Install the PTFE diaphragm with the side marked “FLUID
SIDE” towards the fluid cap.
SRe-check torque settings after pump has been re-started and run a
while.
SVitonRand HytrelRare trademarks of the DuPont Company SKynarRis a trademark of Arkema Inc. SLoctiteRis a registered trademark of Henkel Loctite Corporation S
SSantopreneRis a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. SARORis a registered trademark of Ingersoll-Rand Company S
MATERIAL CODE
[A] = Aluminum
[B] = Nitrile
[C] = Carbon Steel
[CI] = Cast Iron
[Co] = Copper
[D] = Acetal
[E] = E.P.R.
[H] = Hytrel
[K] = Kynar PVDF
[N] = Neoprene
[P] = Polypropylene
[SH] = Hard Stainless Steel
[Sp] = Santoprene
[SS] = Stainless Steel
[T] = PTFE
[U] = Polyurethane
[V] = Viton
637155
ABRASION RESISTANT
CONVERSION KIT
Includes:
93266 (4) [SH] Seat
92757-8 (4) [U] Ball
Service Note: Part no. 98931-T installation tool is available separately for use with items 1 and 2.
V“Smart Parts”, keep these items on hand in addition to the service kits for fast repair and reduction of down time.
66615X-X-C (en)Page 4 of 8
PARTS LIST / 66615X-X-C FLUID SECTION
L637124-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), 93706-1 Key-Lube grease packet, plus items: 2, 3, 9 and 19.
SEAT OPTIONS BALL OPTIONS
“21” L“22” (1-3/4” dia.)
-XXX Seat Qty [Mtl] -XXXBall Qty [Mtl] -XXXBall Qty [Mtl]
-1XX 92760 (4) [A] -X1X92757-1 (4) [N] -X8X92757-8 (4) [U]
-2XX 92776 (4) [SS] -X2X92757-2 (4) [B] -XAX94804 (4) [SS]
-3XX 92924 (4) [P] -X3X92757-3 (4) [V] -XCX92757-C (4) [H]
-4XX 94514 (4) [K] -X4X92757-4 (4) [T] -XEX92757-A (4) [Sp]
-5XX 95676 (4) [C] -X5X92757-5 (4) [E]
-8XX 93266 (4) [SH] -X6X92757-6 (4) [D]
DIAPHRAGM OPTIONS
LService Kit L“7” L“8” L“3” (1/16” x 3/4” o.d.) L“19” (1/8” x 2-3/4” o.d.)
-XXX
-XX = (Ball)
-XX = (Diaphragm) Diaphragm Qty [Mtl] Diaphragm Qty [Mtl] “O” Ring Qty [Mtl] “O” Ring Qty [Mtl]
-XX1637124-X192755-1 (2) [N] ----- --- --- Y325-16 (4) [B] Y325-230 (4) [B]
-XX2637124-X294615-G (2) [B] ----- --- --- Y325-16 (4) [B] Y325-230 (4) [B]
-XX3637124-X392755-3 (2) [V] ----- --- --- Y328-16 (4) [T] Y327-230 (4) [V]
-XX4637124-X494617 (2) [T] 94616 (2) [Sp] Y328-16 (4) [T] Y220-230 (4) [T]
-XX5637124-X592755-5 (2) [E] ----- --- --- Y328-16 (4) [T] 92761 (4) [E]
-XX9637124-X994615-9 (2) [H] ----- --- --- Y328-16 (4) [T] Y327-230 (4) [V]
-XXB637124-XB94615-A (2) [Sp] ----- --- --- Y328-16 (4) [T] 92761 (4) [E]
WETTED PARTS OPTIONS
Aluminum Stainless Steel Cast Iron
6661X0-X, 6661XA-X 6661X1-X, 6661XB-X 6661X2-X, 6661XC-X
N.P.T.F. BSP N.P.T.F. BSP N.P.T.F. BSP
Item Description (size) Qty Part No. Part No. [Mtl] Part No. Part No. [Mtl] Part No. Part No. [Mtl]
15 Fluid Cap (2) 92750 92750 [A] 92773 92773 [SS] 92778 92778 [CI]
16 Manifold (2) 92749 92749-1 [A] 92774 92774-1 [SS] 92777 92777-1 [CI]
HARDWARE OPTIONS
Carbon Steel Stainless Steel
6661X0-, 1-, 2-6661XA-, B-, C-
Item Description (size) Qty Part No. [Mtl] Part No. [Mtl]
5Plate (air side) (2) 92752 [C] 92775 [SS]
26 Bolt (3/8” - 16 x 1-1/4”) (8) Y6-66-C [C] Y6-66-T [SS]
27 Bolt (5/16” - 18 x 2-1/4”) (4) Y6-510-C [C] Y6-510-T [SS]
29 Nut (5/16” - 18) (20) Y12-5-C [C] Y12-5-S [SS]
32 Leg (2) 92759 [C] 92759-1 [SS]
59 Bolt (5/16” - 18 x 2”) (16) 93608 [C] Y6-59-T [SS]
COMMON PARTS
Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]
V1Rod (1) 98720-1 [C]
L2“O” Ring (3/32” x 1” o.d.) (1) Y330-117 [B]
V6Plate (fluid side) (2) 92775 [SS]
(models 6661X0 only) (2) 92752 [C]
L9Washer (0.630” i.d.) (2) 93065 [SS]
14 Screw (5/8” - 18 x 1-1/2”) (2) Y5-107-T [SS]
43 Ground Lug (see page 7) (1) 93004 [Co]
Page 5 of 866615X-X-C (en)
PARTS LIST / 66615X-X-C FLUID SECTION
1
29 ,U
FOR THE
AIR MOTOR SECTION
SEE PAGES 6 & 7
.TORQUE REQUIREMENTS ,
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(14) Diaphragm screw, 65 - 70 ft lbs (88.1 - 94.9 Nm.).
(26) Bolts, 240 - 280 in. lbs (27.1 - 31.6 Nm).
(29) Nuts, 120 - 140 in. lbs (13.6 - 15.8 Nm).
LUBRICATION / SEALANTS
kApply Key-Lube to all “O” rings, “U” Cups & mating parts.
zApply Loctite
R
271 to threads.
UApply anti-seize compound to threads and bolt and nut
flange heads which contact pump case when using stain-
less steel fasteners.
View for 6661XX-XX4-C (PTFE diaphragm) configuration only.
Tab
7k3
COLOR CODE
Diaphragm Ball
Material Color Color
Acetal N / A Orange
E.P.R. Blue (--) Blue (S)
Hytrel Cream Cream
Neoprene Green (--) Green (S)
Nitrile Black Red (S)
Santoprene Tan*Tan
PTFE White White
Polyurethane N / A Red
Viton Yellow (--) Yellow (S)
(--) Stripe (S)Dot
*See item 8 in inset below.
21
19 k
22
26 ,U
16
59 U
15
22
21
19 k
16
27 U
32
14 ,z
9
6
5
2k
Tab
7PTFE
(white)
Santoprene 8
(Green when used as backer)
Air
Side
Fluid
Side
Fluid
Side
Air
Side
Cross Section View of Diaphragms
5
7
2
3
4
1
8
6
Torque Sequence
10 9
3k
26 ,U
Figure 2
66615X-X-C (en)Page 6 of 8
PARTS LIST / 66615X-X-C AIR SECTION
nIndicates parts included in 637118-C Air Section Service Kit.
SERVICE KIT NOTE: Service Kit 637118-C is a general repair kit for all 1” and larger ARO diaphragm pump air motors. It contains extra “O” rings and
extra parts that may not be needed to service this model.
Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]
101 Motor Body (66615X-X, 66617X-X) (1) 94744 [A]
(66616X-X, 66618X-X) (1) 94742 [CI]
n102 “O” Ring (1/16” x 1-1/4” o.d.) (2) Y325-24 [B]
V103 Sleeve (1) 94528 [D]
n104 Retaining Ring, TruArc (1-5/32” i.d.) (2) Y145-26 [C]
105 Screw / Lockwasher (1/4” - 20 x 5/8”)
(models 6661X0-X, 6661X1-X, 6661X2-X)
(8) 93860 [C]
Cap Screw (1/4” - 20 x 5/8”) (models
6661XA-X, 6661XB-X, 6661X5C-X)
(8) Y6-42-T [SS]
106 Lockwasher (1/4”) (models 6661XA-X,
6661XB-X, 6661XC-X only)
(8) Y14-416-T [SS]
107 Plate (2) 93707-1 [SS]
n108 Gasket (with notch) (1) 92878 [B/Ny]
V109 Piston (1) 92011 [D]
n110 “U” Cup (3/16” x 1-3/8” o.d.) (1) Y186-51 [B]
V111 Spool (models 66615X-X, 66617X-X) (1) 92005 [A]
(models 66616X-X, 66618X-X) (1) 93047 [C]
V112 Washer (1.557” o.d.) (5) 92877 [Z]
n113 “O” Ring (small) (1/8” x 1-1/4” o.d.) (5) Y325-214 [B]
n114 “O” Ring (large) (3/32” x 1-9/16” o.d.) (6) Y325-126 [B]
V115 Spacer (4) 92876 [Z]
V116 Spacer (1) 92006 [Z]
n117 Gasket (1) 92004 [B/Ny]
118 Pilot Rod (1) 93309-2 [C]
n119 “O” Ring (1/8” x 3/4” o.d.) (4) 93075 [U]
120 Spacer (3) 115959 [Z]
121 Sleeve Bushing (2) 98723-2 [Bz]
n122 “O” Ring (3/32” x 9/16” o.d.) (2) 94820 [U]
n123 Screw (#8 - 32 x 3/8”) (4) Y154-41 [C]
126 Pipe Plug (1/2 - 14 P.T.F. x 17/32”) (1) Y227-5-L [C]
127 90_Street Elbow (3/4 - 14 N.P.T.) (1) Y43-5-C [C]
128 Pipe Plug (1/8 - 27 P.T.F. x 1/4”) (1) Y227-2-L [C]
197 Button Head Screw (1/4” - 20 x 1/4”) (2) 94987 [SS]
198 Button Head Screw (1/4” - 20 x 3/8”) (1) 94987-1 [SS]
201 Muffler (1) 350-568
231 Pipe Plug (1/4 - 18 N.P.T. x 0.41”) (models
66616X-X and 66618X-X only)
(2) Y17-51-S [SS]
nKey-Lube “O” Ring Lubricant (1) 93706-1
10 Pak of Key-Lube (10) 637175
nService Kits include: Y212-101 (2) Screws (#10 - 32 x 1/4”) used on units mf’d be-
tween 8/90 and 4/92 to retain the pilot bushing.
AIR MOTOR SECTION SERVICE
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.
GENERAL REASSEMBLY NOTES:
SAir Motor Section Service is continued from Fluid Section repair.
SInspect and replace old parts with new parts as necessary. Look for
deep scratches on metallic surfaces, and nicks or cuts in “O” rings.
STake precautions to prevent cutting “O” rings upon installation.
SLubricate “O” rings with Key-Lube.
SDo not over-tighten fasteners, refer to torque specification block on
view.
SRe-torque fasteners following restart.
PILOT VALVE DISASSEMBLY
1. Remove (104) retaining ring.
2. Remove (123) screws and (122) “O” rings.
3. Remove (118) piston rod, (121) sleeve bushing, (119) “O” rings and
(120) spacers from the (101) motor body.
4. Remove (103) sleeve and (102) “O” rings.
PILOT VALVE REASSEMBLY
1. Replace two (102) “O” rings if worn or damaged and reinstall (103)
sleeve.
2. Install one of the (121) sleeve bushings, (119) “O” rings, (120)
spacers and the remaining (121) bushing.
3. Carefully push (118) pilot rod into bushings etc. and retain on each
end with the two (122) “O” rings, retain with (123) screws.
4. Replace (104) retaining rings.
MATERIAL CODE
[A] = Aluminum [CI] = Cast Iron [SS] = Stainless Steel
[B] = Nitrile [D] = Acetal [U] = Polyurethane
[Bz] = Bronze [Ny] = Nylon [Z] = Zinc
[C] = Carbon Steel
MAJOR VALVE DISASSEMBLY
1. Remove (107) plate (or leg depending on model), (108 and 117)
gaskets.
2. On the side opposite the air inlet, push on the inner diameter of (111)
spool. This will force the (109) piston out. Continue pushing the (111)
spool and remove. Check for scratches and gouges.
3. Reach into the air section (exhaust side) and remove (116) spacer,
(115) spacers, (113) “O” rings, (114) “O” rings, (112) washers, etc.
Check for damaged “O” rings.
MAJOR VALVE REASSEMBLY
1. Replace (112) washer, (114) “O” ring and (113) “O” ring onto (115)
spacer and insert etc.
NOTE: Be careful to orient spacer legs away from blocking in-
ternal ports.
2. Lubricate and carefully insert (111) spool.
3. Install (117) gasket and (107).
4. Lubricate and install (110) packing cup and insert (109) piston into
(air inlet side) cavity, the (110) packing cup lips should point outward.
5. Install (108) gasket and replace (107).
V“Smart Parts”, keep these items on hand in addition to the service kits for fast repair and reduction of down time.
Page 7 of 866615X-X-C (en)
PARTS LIST / 66615X-X-C AIR SECTION
MAJOR VALVE
PILOT VALVE
118 k
111
112
k113
k114
115 116
117
119 k
102 k
104
123 H
121
122 k
120
108
109
k110
106
.105
.TORQUE REQUIREMENTS ,
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(105) 40 - 50 in. lbs (4.5 - 5.6 Nm).
LUBRICATION / SEALANTS
kApply Key-Lube to all “O” rings, “U” Cups & mating parts.
HApply Loctite 262 to threads.
zApply Loctite 271 to threads.
gApply Loctite 572 to threads.
See cross section detail, figure 4.
g128
MAJOR VALVE CROSS SECTION DETAIL
109 110 k112 114 k113 k115 111 116
Figure 4
107 126 g
IMPORTANT
BE CERTAIN TO ORIENT (115) SPACER LEGS
AWAY FROM BLOCKING INTERNAL PORTS
WHEN REASSEMBLING AIR SECTION.
197 z
z198
101
g231
104
103 k
107
106
105 ,
H123
121
z197
43
201
127
Figure 3
66615X-X-C (en)Page 8 of 8
TROUBLE SHOOTING
Product discharged from exhaust outlet.
SCheck for diaphragm rupture.
SCheck tightness of (14) diaphragm screw.
Air bubbles in product discharge.
SCheck connections of suction plumbing.
SCheck “O” rings between intake manifold and fluid caps.
SCheck tightness of (14) diaphragm screw.
Low output volume, erratic flow or no flow.
SCheck air supply.
SCheck for plugged outlet hose.
SCheck for kinked (restrictive) outlet material hose.
SCheck for kinked (restrictive) or collapsed inlet material hose.
SCheck 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-col-
lapsing type, capable of pulling a high vacuum.
SCheck all joints on the inlet manifolds and suction connections.
These must be air tight.
SInspect the pump for solid objects lodged in the diaphragm chamber
or the seat area.
DIMENSIONAL DATA
(Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
11-1/2” (292 mm)
19-5/8”
(498 mm)
18-3/8”
(467 mm)
13-1/8” (333 mm)
10-3/4” (273 mm)
2-3/4”
(70 mm)
9” (229 mm)
1/2” Slot (14 mm)
Material Outlet
1-1/2 - 11-1/2 N.P.T.F. - 1 (66615X-X-C, 66616X-X-C)
Rp 1-1/2 (1-1/2 - 11 BSP parallel) (66617X-X-C, 66618X-X-C)
Figure 5
7-5/8”
(194 mm)
12 ”(305 mm)
Material Inlet
1-1/2 - 11-1/2 N.P.T.F. - 1 (66615X-X-C, 66616X-X-C)
Rp 1-1/2 (1-1/2 - 11 BSP parallel) (66617X-X-C, 66618X-X-C)
Air Inlet
1/2 - 14 N.P.T.F. - 1
Air Exhaust Thread
3/4 - 14 N.P.T.F. - 1
14-13/16” (376 mm)
PN 97999-96

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