5 common AODD pump mistakes & how to avoid them

5 Common AODD Pump Mistakes and How to Avoid Them

At Crest Pumps, we know that Air Operated Double Diaphragm (AODD) pumps are one of the most versatile and reliable solutions for handling a wide range of fluids. However, even the toughest pump can lose performance or fail prematurely if it’s not used correctly.

Based on our years of experience supporting customers across the chemical, water treatment and manufacturing industries, here are five common AODD pump mistakes we often see — and how to avoid them.

1. Running the Pump Dry for Too Long

While AODD pumps are designed to run dry without immediate damage, prolonged dry running causes unnecessary wear on diaphragms and check valves.

💡 Crest Tip: If your process regularly runs dry, keep an eye on cycle frequency and consider fitting an air regulator or timer to prevent excessive operation when fluid isn’t present.

2. Incorrect Air Pressure

More air pressure doesn’t always mean more flow. Over-pressurising can stress diaphragms and waste energy, while under-pressurising reduces performance.

💡 Crest Tip: Always operate within the recommended pressure range. A simple air regulator can protect both your pump and your compressed air budget.

3. Using the Wrong Materials for the Application

Material compatibility is one of the most common oversights. Using a diaphragm or body material unsuited to the chemical being handled can lead to swelling, cracking or complete failure.

💡 Crest Tip: If in doubt, speak to our team — we can help you select the right materials for your process to ensure long-term reliability. You can also find our easy to use chemical compatability table here which takes the guesswork out of material selection. 

4. Incorrect Suction and Discharge Line Sizing

Pipework that’s too small restricts flow and increases strain on the pump. Oversized or poorly routed pipework can create air pockets and pulsation.

💡 Crest Tip: Match your line size to the pump’s ports and keep runs short and direct. The fewer bends, the better the performance.

5. Skipping Routine Maintenance

AODD pumps are low-maintenance, but not maintenance-free. Ignoring diaphragm wear or valve condition can lead to performance drops and leaks.

💡 Crest Tip: A quick visual check every few months can make a huge difference. Keep spare diaphragms and valve balls on hand to minimise downtime.

AODD pumps are incredibly forgiving, but a few small changes in setup and maintenance can significantly extend their lifespan and efficiency.

At Crest we’re here to help you get the very best from your equipment — from material selection to long-term support. If you’d like help checking your AODD pump setup or choosing the right model for your process, get in touch with our team today.