ARO 612041 Series User manual

OPERATOR’S MANUAL 612041-X
2” AIR MOTOR
1:1 RATIO
0 - 150 P.S.I. RAN E
INCLUDE MANUAL: S-632 GENERAL INFORMATION PN 97999-624)
INCLUDIN : SPECIFICATIONS, SERVICE KITS, ENERAL INFORMATION, PARTS, TROUBLESHOOTIN
2” DIFFERENTIAL
TRANSFER PUMP
READ THIS MANUAL CAREFULLY BEFORE INSTALLIN ,
OPERATIN OR SERVICIN THIS EQUIPMENT.
It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference.
612042-X
SERVICE KITS
SPECIFICATIONS
Model Series 61204X-X. . . . . . . . . . . . . . . . .
Type Air Operated, transfer pump. . . . . . . . . . . . . . . . . . . . . . .
Ratio 1:1. . . . . . . . . . . . . . . . . . . . . . .
Air Motor Diameter 2’’ 5.08 cm). . . . . . . . . . . .
Stroke 6’’ 15.24 cm). . . . . . . . . . . . . . . . . . . .
Air Inlet female) 1/4 - 18 N.P.T.F. - 1. . . . . . . . . . . . .
Material Inlet immersed. . . . . . . . . . . . . . .
Material Outlet female) 3/4 - 14 N.P.T.F. - 1. . . . . . .
Pump Construction Carbon Steel. . . . . . . . . .
Dimensional Data See Chart. . . . . . . . . . . . .
Weight See Chart. . . . . . . . . . . . . . . . . . . . . .
PERFORMANCE
Air Inlet Pressure Range 0 - 150 p.s.i. 0 - 10.3 bar). . . . . . . .
Fluid Pressure Range 0 - 150 p.s.i. 0 - 10.3 bar). . . . . . . . . .
Maximum Rec’d Cycles / Minute 75. .
Displacement In3Per Cycle 18.8. . . . . .
Volume / Cycle 10.4 oz. 307.7 ml). . . . . . . . . . . . . . . .
Cycles Per Gallon 12.3. . . . . . . . . . . . .
Maximum Working Flow Rate 6 g.p.m. 22.7 l.p.m.). . . .
Maximum Flow Rate 18 g.p.m. 68.1 l.p.m.). . . . . . . . . . .
Noise Level @ 60 p.s.i., 40 c.p.m. 77.8 db A)*. .
* The pumpsoundpressure levelhasbeen updatedto anEquivalentContinuousSound
Level LAeq) to meet the intent ofANSI S1. 13-1971, CAGI-PNEUROP S5.1 usingfour
microphone locations.
ENERAL DESCRIPTION
The Aro 2’’ differential 1:1 ratio transfer pumpsare intended to be used
primarily for oil transfer and delivery systems. It is best to use this pump
with low - medium viscosity fluids. It uses carbon steel and othermateri-
als which make it compatible with most petroleum based lubrication
products.
OPERATIN AND SAFETY PRECAUTIONS
WARNIN Read the General Information Manual for operat-
ing and safety precautions and important information.
PUMP DATA
Figure 1
Material Inlet
Immersed
Air Inlet (female)
1/4 - 18 N.P.T.F. - 1
MODEL 61204X-X
Material Outlet (female)
3/4 - 14 N.P.T.F. - 1
NOTE: Dimensions are shown in inches and mm), supplied for reference only and are typically
rounded up to the nearest 1/16 inch.
MODEL “A” mm) “B” mm) WEIGHT kg)
612041-X 54” 1371.6) 34-5/8” 879.5) 13 lb 5.9)
612042-X 64-1/4” 1631.9) 44-7/8” 1139.8) 14 lb 6.4)
“A”
‘‘B’’
48
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET – BRYAN, OHIO 43506
[phone] FAX[phone] © 2017CCN 99444598
arozone.com
IMPORTANT
This is one of two documents which support the pump. Replace-
ment copies of these forms are available upon request.
=612041-X MODEL OPERATOR’S MANUAL
-S-632GENERAL INFORMATION LUBRICATION PISTON PUMPS
xUse only genuine ARORreplacement parts to assure compatible
pressure rating and longest service life.
x637084 for air motor repair (see page 2).
x637081 for lower pump end (Nitrile) repair (see page 3).
x637083 for lower pump end (PTFE) repair (see page 3).
RELEASED: 10-23-86
REVISED: 4-21-17
(REV: M)

Page 2 of 4 612041-X
PARTS LIST / AIR MOTOR SECTION
Item Description size in inches) Qty Part No. [Mtl]
1 Cap 1) 76073-2 [A]
2 Washer 1) 77290 [C]
“O” Ring 3/32” x 2-5/16” o.d.) 1) Y325-138 [B]
4 Spring 1) 77208 [C]
5 Button 1) 90638 [C]
6 Cylinder 1) 76074-2 [A]
Spacer and Piston Assembly 1) 61088
8 Screw #4 - 40 x 3/8”) 3) Y222-54-C [C]
9 Valve Plate 1) 76090 [C]
10 Piston Assembly 1) 60656 [B/C]
11 Valve Spacer 1) 76856 [D]
Gasket 1) F21-53 [Co]
13 Plunger Tip 1) 77794 [C]
“O” Ring 1/8” x 1-1/4” o.d.) 1) Y325-214 [B]
15 Plunger 1) 76215 [C]
“O” Ring 3/32” x 2-1/16” o.d.) 1) Y325-134 [B]
17 Spring 1) 76070 [C]
18 Pump Body 1) 77807 [A]
“O” Ring .275” x 1.837” o.d.) 1) 77803 [B]
20 Ground Screw #10 - 32 x 1/4”) page 3) 1) 93005 [C]
21 Dowel Pin 3/16” dia. x 1-1/8”) 1) Y148-29 [C]
Parts in Repair Kit 637084
MATERIAL CODE
[A] = Aluminum [CI] = Cast Iron [SS] = Stainless Steel
[B] = Nitrile [Co] = Copper [T] = PTFE
[Br] = Brass [D] = Acetal [U] = Urethane
[C] = Carbon Steel [NY] = Nylon [V] = Viton
1
3
2
4
5
6
8
9
10
11
7
12
13
14
15
17
16
18
19
21
Figure 2
1/4 N.P.T.F. - 1
PUMP DISASSEMBLY
NOTE: All threads are right hand.
1. Place the 2”differential pumpin a vise. Rotate the pumpso the ma-
terial outlet is resting against the vise jaw. CAUTION: Do not clamp
the pump too tightly.
Figure 3
2. Place a strap wrench around the 1) cap and remove the cap. If the
6) cylinder comes off with the 1) cap, place the cap in a vise and
use a strap wrench around the 6) cylinder to unscrew it from the
cap. NOTE: Do not squeeze or use a pipe wrench on 6) cylinder.
3. Remove 3) “O”ring.
4. Usinga strapwrench, asshowninfigure 3, unthreadand remove the
6) cylinder from the 18) pump body.
5. Remove 16) “O”ring from the 18) pump body.
6. Unthread and remove 7) spacer and piston assembly from the 13)
plunger tip.
7. Remove 12) gasket from 13) plunger tip.
9
Figure 4
10
11
8
35
37
38
22
39
continued on page 4)
n3
n7
n12
n14
n16
n19
n

Page 3 of 4612041-X
PARTS LIST / LOWER PUMP SECTION
Item Description size in inches) Qty Part No. [Mtl]
22 Piston Rod 1) 77804 [C]
23 “O” Ring 1/16” x 5/8” o.d.) 1) Y325-14 [B]
24 Plug 1) 79057 [NY]
“O” Ring 3/32” x 2-1/16” o.d.)
models 61204X-1 1) Y325-134 [B]
models 612041-3 1) Y327-134 [V]
“O” Ring 3/32” x 1-7/16” o.d.)
models 61204X-1 1) Y325-124 [B]
models 612041-3 1) Y327-124 [V]
27 Groove Pin 1/8” dia. x 3/4”) 1) Y122-85 [C]
28 Collar 1) 76900 [C]
29 Washer models 612041-3 only) 1) 77910 [C]
Packing models 61204X-1 only) 2) 75649 [U]
“O” Ring 1/16” x 1/2” o.d.)
models 61204X-1 1) Y325-12 [B]
models 612041-3 1) Y327-12 [V]
32 Retaining Ring 1) 77801 [C]
Piston models 61204X-1 1) 75648 [D]
models 612041-3 1) 77827 [T]
34 Suction Tube models 612041-X 1) 77798 [C]
models 612042-1 1) 77814 [C]
35 Washer 1) 77797 [C]
36 Tube 1) 77806 [C]
Cup models 61204X-1 1) 77796 [B]
models 612041-3 1) 77826 [T]
38 Washer 1) 77800 [C]
39 Nut 3/8” - 24) 1) Y115-14 [SS]
40 Stem 1) 76093 [C]
41 Plate 1) F58-3 [C]
42 Valve Body 1) F259-1 [CI]
43 Foot Valve Asm includes items 40 - 42) 1) 60657
44 Bung Adapter includes item 45) 1) 60870 [C]
45 Screw 1/4” - 20 x 1-1/2”) 1) Y197-158-C [C]
48 Needle Valve see figure 1) 1) 92818 [Br]
20
23
24
22
25
26
34
35
41
42
40
32
31
30
33
28
27
43
37
38
39
36
29 33
612041-3
3/4 N.P.T.F. - 1
Figure 5
-25
-26
-30
-31
-33
-37
-Parts included in 637081 service kit (models 61204X-1).
Parts included in 637083 service kit (models 612041-3).

PN 97999-93
Page 4 of 4 612041-X
PUMP DISASSEMBLY (continued)
NOTE: Perform steps 8 thru 10 only if 7) spacer and piston assembly
needs servicing.
8. Remove the three 8) screws fromthe 11)valve spacer see figure 4).
9. Remove the 9) valve plate.
10. Remove the 11) valve spacer from the 10) piston assembly.
11. Unthread 13) plunger tipfromthe 15) plungerby usinga wrenchon
the flats ofthe 13) plunger tip and a strapwrench onthe 15) plung-
er. CAUTION:Place the strap wrenchonthe very uppermostpartof
the 15) plunger.
12. Remove 14) “O”ring.
13. Remove 21) dowel pin.
14. Remove 13) plunger tip.
15. Remove 15) plunger.
16. Remove 17) spring from the 18) pump body.
17. Remove 19) “O”ring from the 18) pump body.
18. Using a pipe wrench, unthread and remove the 34) suction tube
from the 18) pump body. CAUTION: Place the pipe wrench on the
very upper most or very lower most part of the 34) suction tube. Do
not damage or dent this tube.
19. Remove 25) “O”ring from the 18) pump body.
20. Grasp the 22) piston rod and remove by pulling straight out.
21. Using a strap wrench on 36) tube, unthread and remove from 18)
pump body. CAUTION: Do not damage or dent this tube.
22. Remove 26) “O”ring from 18) pump body.
23. Remove 24) plug and 23) “O”ring.
24. Clampthe 43) intake valve assemblyina vise. Usinga strap wrench
on 34) suction tube, unthread and remove from valve assembly.
CAUTION: Do not damage or dent this tube.
25. Usinga wrench onflatsof 22) pistonrod, unthread and remove 39)
nut see figure 4).
26. Remove 38) washer, 37) cupand 35) washer from 22) pistonrod.
27. Remove 32) retaining ring from the 22) piston rod, using retaining
ring pliers.
28. Remove 33) piston from 22) piston rod.
29. Remove two 30) packings where applicable).
30. Remove 31) “O”ring from 22) piston rod.
NOTE: Do not remove 27) groove pin and 28) collar from 22) piston
rod unless damage is evident. Remove 27) groove pin, releasing 28)
collar.
PUMP REASSEMBLY
1. Insertthe 11) valve spacer thruthe bottomofthe 10) pistonassem-
bly see figure 4).
2. Place the 9) valve plate on top ofthe 10) piston assembly, aligning
the three holes with the posts of 11) valve spacer.
3. Fasten the 9) valve plate down using the three 8) screws. Laythis
assembly aside for the moment.
4. Place the 28) collar on the 22) piston rod and secure with 27)
groove pin.
5. Assemble 29) washer next to 28) collar on 22) piston rod.
6. Grease and assemble 31) “O”ring to 22) piston rod.
7. Assemble two 30) packings to 33) piston where applicable).
8. Assemble 33) piston to 22) piston rod, securing with 32) retaining
ring.
9. Assemble 35) washer, 37) cup lips up) and 38) washer onto 22)
piston rod, securing with 39) nut see figure 4).
10. Grease and assemble 23) “O” ring into 24) plug and screw 24)
plug into 18) pump body.
11. Place the 18) pumpbody ina vise androtate it so the materialoutlet
is resting against the vise jaw. CAUTION: Do not clamp the pump
body too tightly.
12. Grease and assemble 26) “O”ring to 18) pump body.
13. Thread 36) tube onto 18) pump body and tighten, using a strap
wrench.
14. Assemble the 22) piston rod up thru the 18) pump body.
15. Grease and assemble 25) “O”ring to 18) pump body.
16. Thread the 34) suction tube to the 18) pump body and tighten, us-
ing a strap wrench.
17. Thread the 43) intake valve assembly to the 34) suction tube and
tighten.
18. Grease and assemble 19) “O”ring into 18) pump body.
19. Place 17) spring into 18) pump body.
20. Assemble 15) plunger over 22) piston rod.
21. Assemble 13) plungertipto 22) pistonrodandinsert 21) dowelpin
to secure plunger tip.
22. Grease and assemble 14) “O”ring to 13) plunger tip.
23. Pull 15) plungerup and thread 13) plunger tip to plunger andtight-
en by using a wrench on flats of 13) plunger tip and a strapwrench
on 15) plunger.
24. Place the 12) gasket over the end of 13) plunger tip.
25. Thread the 7) spacer and piston assembly onto the 13) plunger tip
and tighten.
26. Grease and assemble 16) “O”ring to 18) pump body.
27. Thoroughly grease the inside of the 6) cylinderand assemble over
the 7) spacer and piston assembly, threading onto the 18) pump
body.
28. Assemble 2) washer, 3) “O”ring, 4) spring and 5) button into 1)
capandassemble capto 6) cylinder, tighteningusinga strapwrench.
TROUBLE SHOOTIN
Pump continually cycles.
xCheck for empty material supply. Disconnect the air (from thepump)
replenish material supply.
xCheck for worn or damaged (30) packing or (33) piston.
Material on one stroke only (fast downstroke).
xThe intake valve assembly may not be checking or sealing properly.
Remove the intake valve assembly and inspect. If the valve assem-
bly is damaged, replace with new parts. If the valve assembly is not
damaged, thoroughly clean and reassemble to the pump (see pump
instructions).
Material on one stroke only (fast upstroke).
xCheck for worn or damaged (37) cup. Replace cup (see pump
instructions and figure 4).
Material leakage out the top of the pump body.
xCheck for worn or damaged (30) packing or (33) piston.
Air leakage out of the exhaust holes. (See Air Motor Instructions)
xCheck to see if the (9) valve plate is loose or has become disas-
sembled from the (11) valve spacer.
xCheck for worn or damaged (10) piston assembly.
xCheck for worn or warped (9) valve plate.
xWorn or damaged (14) “O” ring. Replace (14) “O’’ ring.