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Page 6 of 12 PD03P-XXX-XXX (en)
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Indicates parts included in 637428 Air Section Repair Kit.
Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]
101 Center Body (1) 96466 [PPG] 140 Valve Insert (1) 93276 [CK]
103R Cover
(right side)
(1) 96488 [D] 141 Valve Plate (1) 96173 [CK]
103L Cover
(left side)
(1) 96489 [D]
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144 “U” Cup Packing
(1/8” x 3/4” o.d.)
(2) Y187-47 [B]
107 Plug, Small (1) 96353 [D]
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166 “O” Ring
(1/16” x 1-1/4” o.d.)
(1) Y325-24 [B]
111 Major Valve Spool (1) 95919 [D]
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167 Pilot Piston
(includes 168 and 169)
(1) 67382 [D]
118 Actuator Pin (2) 94874-1 [SS] 168 “O” Ring
(1/16” x 7/16” o.d.)
(2) 96459 [U]
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121 Washer (2) 96092 [D] 169 “U” Cup Packing
(1/8” x 5/8” o.d.)
(1) 96384 [U]
123 Screw
(#4 - 20 x 1/2”)
(12) 96093 [SS] 170 Spool Bushing (1) 96090 [D]
129 Mu er Ba e (1) 96542 [P]
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171 “O” Ring
(1/16” x 13/16” o.d.)
(2) Y325-17 [B]
130 Gasket (1) 95931 [SY]
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173 “O” Ring
(3/32” x 7/8” o.d.)
(2) Y325-115 [B]
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132 Air Manifold Gasket (1) 96214-1 [B]
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174 “O” Ring
(3/32” x 11/32” o.d.)
(2) Y325-105 [B]
134 Flange Bolt
(1/4” - 20 x 3”)
(4) 96487 [SS]
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200 Porting Gasket (1) 96364 [B]
135 Valve Block (1) 96204 [PPG]
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232 “O” Ring
(1/16” x 3/8” o.d.)
(4) Y325-10 [P]
136 Plug, Large (1) 96352 [D] 236 Nut
(1/4” - 20)
(4) Y12-4-S [SS]
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137 “O” Ring
(1/16” x 1-5/8” o.d.)
(3) Y325-29 [B]
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138 “U” Cup Packing
(1/8” x 1” o.d.)
(1) 94395 [U]
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Lubriplate FML-2 Grease (1) 94276
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139 “U” Cup Packing
(1/8” x 1-7/16” o.d.)
(1) 96383 [U] Lubriplate Grease, 10 Pack 637308
PARTS LIST / PD03P-XXX-XXX AIR MOTOR SECTION
MATERIAL CODE
[B] = Nitrile [PPG] = Glass Filled Polypropylene
[CK] = Ceramic [SS] = Stainless Steel
[D] = Acetal [SY] = Syn-Seal
[P] = Polypropylene [U] = Polyurethane
DIAPHRAGM PUMP SERVICE
GENERAL SERVICE NOTES:
Inspect and replace old parts with new parts as neces-
sary. Look for deep scratches on metallic surfaces, and
nicks or cuts in “O” rings.
Tools needed to complete disassembly and repair:
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),
“O” ring pick.
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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) 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)
diaphragms and (5) washer from (1) connecting rod. Do
not mar surface of connecting rod.
1.
2.
3.
4.
5.
6.
7.
8
.
FLUID SECTION REASSEMBLY
Reassemble in reverse order.
Lubricate (1) connecting rod with Lubriplate or equiva-
lent “O” ring lubricant.
Install (5) washers with i.d. chamfer toward diaphragm.
When replacing PTFE diaphragms, install the 96533-A
Santoprene diaphragm behind the Te on diaphragm.
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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.
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PILOT VALVE DISASSEMBLY
Remove (123) screws, releasing (103) covers, (121) wash-
ers, (118) actuator pins and (167) pilot piston.
Remove (170) spool bushing and inspect inner bore of
bushing for damage.
1.
2
.
PILOT VALVE REASSEMBLY
Clean and lubricate parts not being replaced from ser-
vice kit.
Assemble (171) “O” rings to (170) bushing and assemble
bushing 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 as-
sembly.
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).
1.
2.
3.
4.
5
.
MAJOR VALVE DISASSEMBLY
Unthread (123) screws, releasing (129) mu er ba e.
Unthread (134) bolts and pull (135) valve block and com-
ponents 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.
3.
4.