Ingersoll-Rand 651785 User manual

HIGH PRESSURE
MATERIAL REGULATOR
OPERATOR’S MANUAL 651785
INCLUDING: OPERATION, INSTALLATION AND MAINTENANCE RELEASED: 7-20-14
REVISED: 11-8-17
(REV: B)
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.
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET – BRYAN, OHIO 43506
[phone] FAX [phone] © 2017 CCN 47522184001
arozone.com
SERVICE KITS
yUse only genuine ARORreplacement parts to assure
compatible pressure rating and longest service life.
yFluid diaphragm kit 61962-1 can be ordered separately
(see page 4).
SPECIFICATIONS
Model Series .............. . . . 651785
Type ......................... Downstream
Material Inlet (female)......... 3/8 - 18 NPTF - 1
Material Outlet (female)....... 3/8 - 18 NPTF - 1
Dimensional Data . . . . . . . . . . . see page 8
PERFORMANCE DATA
Regulated Pressure Range . . . . . . . 75 - 450 psig (5.2 - 31.1 bar)
Maximum Regulated Pressure . . 450 psig (31.1 bar)
Maximum Inlet Pressure. . . . . . . . . . 3000 psig (206.9 bar)
Maximum Temperature Limits . . . 0_to 200_F(-18_to 93_C)
Figure1

Page 2 of 8 651785 (en)
YRead and heed all Warnings and Safety Precautions
before operation of this unit.
YUse only genuine ARO replacement parts to assure
compatible pressure rating and longest service life.
YBe certain anyone operating this equipment or fluid
system has been trained to use it safely.
WARNING
HIGH PRESSURE DEVICE. IMPROPER
USAGE OF THIS EQUIPMENT COULD RESULT IN
SERIOUS INJURY. The possibility of injection into
the flesh is a potential hazard. Wear approved
safety glasses or face shield and other equipment as
needed to prevent injury. Never allow any part of the
human body to come in front of or in contact with
the material outlet, the tip, or the material outlet
of the dispensing device. An injection injury can be
serious. If an injection accident should occur, it is very
important that you contact a qualified physician for
immediate treatment.
WARNING
MISAPPLICATION HAZARD. DO NOT USE
THE REGULATOR WHEN THE FLUID INLET PRESSURE
IS TOO HIGH FOR THEDESIGNED OPERATING RANGE.
Excessive inlet pressure can cause a Lock-Out
situation. Lock-Out occurs whenthe inlet pressure
isbeyondthe regulator’s springcapacity. THE
VALVE WILL NOT OPEN. Attempts to disassemble
componentswhile in a Lock-Out condition mayresult
in injury.
WARNING
COMPONENT RUPTURE. DO NOT OPERATE
REGULATOR AT AN INLET PRESSURE GREATER THAN
SPECIFIED. To avoid possible damage or personal
injury, DO NOT operate this unit at pressure higher
than the stated operating range as it appears on the
model plate.
WARNING
DISASSEMBLY HAZARD. DO NOT
DISASSEMBLE THIS REGULATOR WHEN IT IS UNDER
PRESSURE. RELIEVE PRESSURE IN THE PUMPING SYSTEM
BEFORE ATTEMPTING SERVICE OR DISASSEMBLY
PROCEDURES. Disconnect air lines and carefully bleed
pressure off the system. Be certain the system is not
maintaining pressure due to amaterial restriction in the
hose, line, dispensing device, or the spray or extrusion
tip. Failure to relieve pressure both up stream and
downstream may result in an injury upon disassembly.
WARNING
BONNET REMOVAL HAZARD. DO NOT
ATTEMPT TO REMOVE THE FOUR BONNET RETAINING
BOLTS WITHOUT FIRST RELIEVING THE TENSION ON THE
MAIN SPRING. Failure to relieve tension could result in an
accident upon disassembly.
WARNING
PREVENT FIRES. KEEP SOLVENTS AWAY
FROM HEAT, SPARKS OR OPEN FLAME. Keep containers
closed when not in use.Whenpumping, flushing or
recirculating volatile solvents, be certain the area is
adequately ventilated.
CAUTION
FLUSH SUPPLY LINE. Before installing
fluid regulator, blow the supply lines clear and flush
to remove contaminates.
OPERATING AND SAFETY PRECAUTIONS INSTALLATION
yRefer to the typical installation view which best applies.
yLocate the regulator as close as possible to the spray gun
or dispensing device for best pressure control.
yIdentify the regulator INLET / OUTLET (flow direction).
The regulator is marked with an arrow on the body base
(see gure 8).
yWhen flexible fluid lines are used, mount the regulator
securely using the (2) 1/4” - 20 threaded holes in the base
(see gure 8).
yFlush supply line before installing regulator.
TYPICAL DEAD END SYSTEM
Filter Down Stream
Regulator
Down Stream
Regulator
Figure2
Figure3
TYPICAL RECIRCULATING SYSTEM
Back Pressure
Regulator
Back Pressure
Regulator
Filter
Heater
Back Pressure
Regulator
Down
Stream
Regulator
Down
Stream
Regulator
OPERATING INSTRUCTIONS
Refer to page 4 and 5 for parts reference.
yTo INCREASE outlet pressure, turn the (6) adjusting screw
CLOCKWISE (see gure 4).
yTo DECREASE outlet pressure, turn the (6) adjusting
screw COUNTERCLOCKWISE (see gure 4).
NOTE: ARO Part Y106-109 Allen wrench is included to make
necessary pressure adjustments.
FLUSH-OUT FEATURE (see gure 5).
yFlush the regulator periodically. The interval may vary de-
pending on the amount and type of material used.
yBy using a wrench and “flush-out” plug (provided), the
operator is able to move the entire spindle downward
and force the ball off the seat which should purge the
regulator of particle build-up.
NOTE: The ush-out procedure temporarily overrides the
adjusted pressure. It will not, however, aect the regulator
setting when ushing operation is completed.
FLUSH-OUT PROCEDURE
1. Remove spray gun or dispensing device, this will allow
any particles to clear from the system.
2. Insert (30) flush-out plug and turn clockwise until it
touches the (4) washer (see view on page 5).
3. Turn up to two turns maximum. This will allow the ball
to unseat and pass material at free flow (unregulated).
DO NOT attempt to turn further to avoid damage.
4. Turn the plug back to its original position.
SEAT PLUG FEATURE
The (29) plug located at the base of the regulator can be
removed for access to the ball and seat assembly for clean-
ing and inspection for wear. With this feature, the regulator
EXCESSIVE AIR PRESSURE
STATIC SPARK
HAZARDOUS MATERIALS
HAZARDOUS PRESSURE

651785 (en) Page 3 of 8
REGULATOR DISASSEMBLY
FOR “WARNINGS”, REFER TO “OPERATING AND SAFETY
PRECAUTIONS” ON PAGE 2 FOR DETAILS.
BEFORE SERVICING, READ “WARNING: DISASSEMBLY
HAZARD”. FOUND ON PAGE 2.
TOOLS REQUIRED: Small bench vise, 5/32” allen wrench, 3/8”
allen wrench, torque wrench and Loctite 242.
NOTE: It is not always necessary to remove the regulator
from the uid line to service or inspect only the valve section.
BEFORE DOING ANY IN-LINE SERVICE, ALL FLUID PRES-
SURE MUST BE RELIEVED. HEED ALL WARNINGS FOUND
ON PAGE 2.
VALVE SEAT NOTE: Before deciding to order a repair kit to
service the regulator, check the easiest things rst. Remove
and inspect the valve seat for dirt, foreign matter, damage or
wear (step 1).
1. Remove the (29) seat plug and (28)“O”ring, releasing (27)
ow tube, (26) spring, (25) ball, (24) seat and (23)“O” ring.
2. Remove four (1) bolts and (2) lock washers, releasing (3)
housing.
NOTE: The (6) adjusting screw [with (8) adjustment nut], (5)
thrust bearing and (4) washer are retained by (7) plate, which
is pressed into place. It should not be necessary to disassem-
ble these parts during normal service.
3. Remove (11) plate and (10) spring from (3) housing.
4. Remove (15) cap screws, releasing (16) plate.
5. Remove the stem / diaphragm / piston assembly.
6. Place the assembly in a vise, clamping on ats of (21)
stem assembly.
7. Using a 5/32” Allen wrench, remove the (12) cap screw,
releasing (13) lock washer, (14) piston, (17 and 18) dia-
phragms and (19) “O” ring.
does not have to be unthreaded from the pumping system.
Be certain to relieve system pressure (See “WARNING: DISAS-
SEMBLY HAZARD”).
MAINTENANCE
yDisassembly should be done on a clean work bench and
use clean cloths.
yIf replacement parts are necessary, refer to the parts list
and drawings on pages 4 and 5.
yUpon reassembly, lubricate parts and use Loctite where
indicated. Follow the torque specications as shown.
yService kits are available which include parts typically
needed for an overhaul.
yKeep good records of service activity and include the
regulator in a preventive maintenance program.
yCertain ARO “Smart Parts” are indicated with a “V” in the
parts list, these parts should be available for fast repair
and reduction of down time.
VIEW OF SPRING
ADJUSTMENT PROCEDURE.
Figure 4
VIEWOFFLUSH-OUT PLUG
Figure5
TROUBLE SHOOTING
No uid pressure.
yCheck for damaged or worn diaphragms.
yLook for possible obstruction by hardened material or
foreign matter, periodically use the regulator “ush-out”
feature. Use a uid lter upstream from the regulator.
Pressure creeps above the setting when system is dead
ended and in a static (no ow) mode.
yCheck for dirty seat and clean as appropriate.
yCheck for worn or damaged seat and replace if necessary.
Outlet pressure drops below setting.
yCheck pump for proper operation and check for possible
leakage problems.
yLook for a clogged supply line problem, ush the supply
line.
Fluid leakage from spring housing.
yCheck the (1) bolts and the (15) cap screws and re-torque
as needed.
yCheck for damaged diaphragm, replace as needed.
Regulator will not function, even when dispensing de-
vice is opened.
yCheck for possible obstruction in the uid line.
yInlet pressure is too high causing a “Lock-Out” situation.
Read “WARNING: MISAPPLICATION HAZARD” found on
page 2.

Page 4 of 8 651785 (en)
PARTS LIST / 651785 REGULATOR
1 Bolt (7/16” - 20 x 5-1/2”) (4) 93487-1 [C]
2Lock Washer (7/16”) (4) Y79-716 [C]
3 Housing (1) 93534- 1 [ZA]
4Washer (1) 93485-1 [C]
5 Thrust Bearing (1) 93484-1 [C]
6 Adjusting Screw (1) 93486-1 [C]
7 Plate (1) 93818 [SS]
8 Adjustment Nut (1) 93481-1 [C]
9 Spring Stop (1) 96348-5 [SS]
10 Spring (1) 93638- 1 [C]
11 Plate (1) 93820 [C]
12 Cap Screw (#10 - 32 x 7/8”) (1) Y191-107 [C]
13 Lock Washer (#10) (1) Y14-10 [C]
14 Piston (1) 93821 [C]
15 Cap Screw (7/16”- 20 x 7/8”) (2) Y157-778 [C]
16 Plate (1) 93532-1 [C]
`17 Diaphragm (0.048” thick, cream) (1) 93498-1 [H]
`18 Diaphragm (0.020” thick, white) (1) 93497-1 [T]
`19 "O” Ring (1/16” x 9/16” o.d.) (1) Y328-13 [T]
`20 "O” Ring (3/32” x 1-3/8” o.d.) (1) Y328-123 [T]
V21 Stem Assembly (1) 92985 [SS/TC]
22 Base (1) 93541-1 [SS]
V23 "O” Ring (1/16” x 5/8” o.d.) (1) Y328-14 [T]
V24 Seat (1) 93558-1 [TC]
V25 Ball (0.2500” dia.) (1) 93561-1 [TC]
V26 Spring (1) 93881 [SS]
V27 Flow Tube (1) 93489-1 [SS]
28 "O” Ring (0.097” x 0.949” o.d.) (1) 93492-1 [T]
V29 Seat Plug (includes item 28) (1) 62168 [SS]
30 Flush Plug (not shown) (1) 93819 [C]
31 3/8” Allen Wrench (not shown) (1) Y106-109 [C]
`
Items included in Diaphragm Kit 61962-1
MATERIAL CODE
[C] = Carbon Steel
[H] = Hytrel
[SS] = Stainless Steel
[T] = PTFE
[TC] = Tungsten Carbide
[ZA] = Zinc / Aluminium Alloy
Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]
REGULATOR REASSEMBLY
Also refer to parts list and views on pages 4 and 5.
1. Place the (21) stem assembly in a vise, clamping on the
ats.
2. Assemble the (19) “O” ring to the groove in the (21) stem
assembly.
3. Assemble the (18) white diaphragm (0.020” thick) and
the (17) cream diaphragm (0.048”thick) onto the (21)
stem assembly. NOTE: Assemble the white diaphragm
onto the stem assembly rst.
4. Assemble the (14) piston to the stem assembly.
5. Align the notches in the diaphragms and secure the
assembly with the (13) lock washer and (12) cap screw.
NOTE: Tighten (12) cap screw to 65 - 75 in. lbs (7.3 - 8.5
Nm).
SERVICE HINT: Use the (15) cap screw to help align the
diaphragms.
6. Remove the assembly from the vise.
7. Place the (22) base in a vise, clamping on ats.
8. Place the (20) “O” ring in the groove in the (22) base.
9. Assemble the stem / diaphragm / piston assembly to the
(22) base, aligning the bolt holes.
10. Apply Dri-Slide to the (14) piston and assemble (16)
plate over piston, aligning bolt holes.
11. Apply Loctite 242 to threads of (15) cap screws
and assemble to (22) base, securing (16) plate.
NOTE: Tighten the cap screws alternately and evenly.
First tighten snug, then tighten to 20 - 25 ft lbs (27.1 -
33.9 Nm), then tighten to 50 - 55 ft lbs (67.8 - 74.6 Nm).
12. Place the (11) plate (ball side down) into the hex of the
(12) cap screw.
13. Assemble the (10) spring to the (11) plate and assemble
the (9) spring stop over the spring.
14. Assemble the (3) housing and components to the (16)
plate, securing with (2) lock washers and (1) bolts.
NOTE: Apply Loctite nickel anti-seize to threads of bolts
then tighten alternately until snug, then torque to 20 -
25 ft lbs (27.1 - 33.9 Nm).
15. Assemble (23) “O” ring, (24) seat and (27) ow tube into
(22) base.
16. Assemble the (25) ball and (26) spring (small end against
ball) into (27) ow tube.
17. Assemble (28) “O” ring to (29) seat plug and assemble
seat plug to (22) base.
V“Smart Parts” keep these items on hand in addition to the Service Kits for fast repair and reduction of down time.
SERVICE NOTE: “Dri-Slide”, FXR is a commercially available Anti-Rust lubricant (contains 9% Molybdenum Disulde) or Molybdenum Disulde Powder with or without light oil carrier.

651785 (en) Page 5 of 8
Figure 6
.TORQUE REQUIREMENTS ,
(1)Bolt, torque alternately. Firsttorque snug, then
to 20 -25ftlbs (27.1-33.9Nm).
(12) Cap screw65-75 in.lbs (7.3 -8.5 Nm).
(15) Cap screw,torque alternately. Firsttorque snug,
then to 20 -25ftlbs (27.1-33.9 Nm),then50-55
ft lbs(67.8-74.6Nm).
¡
ApplyDri-Slide upon assembly.
© Apply Loctitenickel anti-seize to threads.
¢ Apply Loctite 242 to threads.
£ Apply 40036 grease.
LUBRICATION -- SEALANTS
28
27
26
25
24
23
22
21
18
16
15 ,¢
13
12 ,
10
9
8
£
6£
2
1,©
NOTE: DO NOTOVERTIGHTEN FASTENERS.
3
4
£5
7
11
¡14
17
19
20
29
MATERIAL CODE
[C]= Carbon Steel
[H] = Hytrel
[SS] =Stainless Steel
[T] =PTFE
[TC] =Tungsten Carbide
[ZA]=Zinc /Aluminum Alloy
PARTS VIEW / 651785 REGULATOR

Page 6 of 8 651785 (en)
Figure7
CROSS SECTION

651785 (en) Page 7 of 8
DIMENSIONAL DATA
Figure8
3 - 7/32” (81.7 mm)
1-3/32”
(27.8 mm)
7-27/32”
(198.8 mm)
1-11/16”
(42.8 mm)
2-5/16”
(58.7 mm)
1/4” -20 UNC -2B(2)
Flow Direction Marking

Page 8 of 8 651785 (en)