OPERATOR’S MANUAL
670042
RELEASED:
REVISED:
(REV. 02)
1-25-07
8-27-08
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
1/2" DIAPHRAGM PUMP
U.L. LISTED, 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
637448 for fluid section repair (see page 4).
637428 for air section repair (see page 6).
PUMP DATA
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670042
Application . . . . . . . . . . . . . . . Diesel Fuel, Kerosene, Aviation Fuel,
Fuel Oil and Unleaded Fuel.
Pump Type. . . . . . . . . . . . . . . . U.L. Listed Metallic Air Operated
Double Diaphragm for use with Pe-
troleum Product Dispensing Systems
Material. . . . . . . . . . . . . . . . . . . see Model Description Chart
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36 lbs (4.70 kgs)
Maximum Air Inlet Pressure . . . . . . . . . . . 50 p.s.i.g. (3.4 bar)
Maximum Material Inlet Pressure. . . . . . 10 p.s.i.g. (0.69 bar)
Maximum Outlet Pressure . . . . . . . . . . . . . 50 p.s.i.g. (3.4 bar)
Air Consumption @ 40 p.s.i.. . . . . . . . . . . . . 1 c.f.m. / gallon (approx.)
(flooded inlet)
Maximum Flow Rate
. . . . . 12.0 g.p.m. (45.4 l.p.m.)
Displacement / Cycle @ 100 p.s.i.g. . . . . 0.039 gal. (0.15 lit.)
Maximum Particle Size . . . . . . . . . . . . . . . . 3/32”dia. (2.4 mm)
Maximum Temperature Limits (diaphragm / ball / seat mate-
rial)
Viton®. . . . . . . . . . . . . . . . . . . . . . . . . -40° to 350° F (-40° to 177° C)
Dimensional Data. . . . . . . . . . . . . . . . . . . . . . see page 8
Noise Level @ 70 p.s.i., 60 c.p.m.. . . . . . . . . 75.0 db(A)
c
Figure 1
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-PNEUROP S5.1 using four microphone locations.
c
MODEL DESCRIPTION CHART
Center Section Material
Aluminum
Fluid Connection
1/2 - 14 N.P.T.F. - 1
Fluid Cap & Manifold Material
Aluminum
Hardware Material
Stainless Steel
Seat Material
Aluminum
Ball Material
Viton
Diaphragm Material
Viton
INGERSOLL RAND COMPANY LTD
P.O. BOX 151 y ONE ARO CENTER y BRYAN, OHIO 43506-0151
ꢀ (800) 276-4658 y FAX (800) 266-7016
© 2008
CCN 15260748
fluids.ingersollrand.com
ply, 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.
When the diaphragm pump is used in a forced-feed (flooded
inlet) situation, it is recommended that a “check valve” be in-
stalled at the air inlet.
GENERAL DESCRIPTION
The ARO U.L. listed pump for pumping petroleum products, offers
high volume delivery at low air pressures and easy self-priming.
This model is designed specifically for transfer, bulk un-loading
or fueling applications. It includes a pressure relief valve (per U. L.
Specification 79) which restricts the fluid outlet pressure to under
50 p.s.i. (3.4 bar). The relief valve must be plumbed to return the
bleed off fuel to the storage container.
y
y
Secure the diaphragm pump legs to a suitable surface to insure
against damage by vibration.
Air operated double diaphragm pumps utilize a pressure differen-
tial in the air chambers to alternately create suction and positive
fluid pressure in the fluid chambers, ball checks insure a positive
flow of fluid.
Pump cycling will begin as air pressure is applied and it will con-
tinue to pump and keep up with the demand. It will build and
maintain line pressure and will stop cycling once maximum line
pressure is reached (dispensing device closed) and will resume
pumping as needed.
MAINTENANCE
Certain ARO “Smart Parts” are indicated which should be avail-
able for fast repair and reduction of down time.
Provide a clean work surface to protect sensitive internal mov-
ing parts from contamination from dirt and foreign matter dur-
ing service disassembly and reassembly.
Keep good records of service activity and include the pump in
preventive maintenance program.
Service kits are available to service two separate diaphragm
pump functions: 1. AIR SECTION, 2. FLUID SECTION. The Fluid
Section is divided further to match typical active Material Op-
tions.
Before disassembling, empty captured material in the outlet
manifold by turning the pump upside down to drain material
from the pump.
y
y
y
y
AIR AND LUBE REQUIREMENTS
WARNING EXCESSIVE AIR PRESSURE. Can cause pump dam-
age, personal injury or property damage. The air supply
must be limited to 50 p.s.i.g. (3.4 bar) maximum inlet air
y
pressure.
A filter capable of filtering out particles larger than 50 microns
should be used on the air supply. There is no lubrication re-
quired other than the “O” ring lubricant which is applied during
assembly or repair.
If lubricated air is present, make sure that it is compatible with
the “O”rings and seals in the air motor section of the pump.
y
y
DIAPHRAGM PUMP SERVICE
GENERAL SERVICE NOTES:
Inspect and replace old parts with new parts as necessary. Look
for deep scratches on metallic surfaces, and nicks or cuts in “O”
rings.
y
Tools needed to complete disassembly and repair:
y
INSTALLATION
7/8” socket or wrench, 1/2” socket or wrench, 3/8” socket or
wrench, 3/8” Allen wrench, 10 mm Allen wrench, T-10 Torx
screwdriver, torque wrench (measuring inch pounds), “O”
ring pick.
y
IMPORTANT
Requirements for the installation are included in the Flam-
y
mable and Combustible Liquids Code, NFPA No. 30, Automo-
tive and Marine Service Station Code, NFPA No. 30A and the
National Electric Code, ANSI / NFPA No. 70.
FLUID SECTION DISASSEMBLY
1. Remove (61) top manifold.
2. Remove (19) “O”rings, (21) seats, (12) washers and (22) balls.
3. Remove (60) bottom manifold.
4. Remove (19) “O”rings, (21) seats, (12) washers and (22) balls.
5. Remove (15) fluid caps.
6. Remove (14) bolt, (6) diaphragm washer, (7) diaphragms and (5)
washer.
7. Remove (1) connecting rod from air motor.
8. Carefully remove remaining (14) bolt, (6) diaphragm washer, (7)
diaphragm and (5) washer from (1) connecting rod. Do not mar
surface of connecting rod.
A fluid return hose which is compatible with the fluid being
pumped must be installed to the relief valve on the outlet
manifold to return fluid back to the supply tank or pump inlet.
The pump must be grounded to prevent static discharge.
Grounding may be accomplished through the legs or to the
ground lug provided on the pump.
y
y
OPERATING INSTRUCTIONS
The pump should never be operated at pressures exceeding 50
p.s.i.g. (345 kPa) inlet air pressure. This pump is equipped with a
pressure relief valve on the material outlet manifold which will
open at 40 +/-4 p.s.i. (2.76 bar) to relieve pressure increases in
the outlet hoses / plumbing caused by thermal expansion or
other external forces.
y
FLUID SECTION REASSEMBLY
Reassemble in reverse order.
Lubricate (1) connecting rod with Lubriplate® or equivalent “O”
ring lubricant.
Connecting rod (1) should be installed using 96571 bullet, in-
cluded in service kit.
Install (5) washers with i.d. chamfer toward diaphragm.
y
y
Always flush the pump with a solvent compatible with the ma-
terial being pumped if the material being pumped is subject to
“setting up”when not in use for a period of time.
y
y
y
Disconnect the air supply from the pump if it is to be inactive
for a few hours.
The outlet material volume is governed not only by the air sup-
y
y
Viton® is a registered trademark of the DuPont Company Loctite® and 242® are registered trademarks of Henkel Loctite Corporation
y
y
y
Lubriplate® is a registered trademark of Lubriplate Division (Fiske Brothers Refining Company) ARO® is a registered trademark of Ingersoll-Rand Company
y
y
y
670042 (en)
Page 3 of 8
PARTS LIST / 670042 FLUID SECTION
637448 Fluid Section Service Kits include: 22 balls, 7 diaphragms, and item 19 (listed below) plus items 144, 174 and 94276 Lubri-
plate FML-2 grease (page 6).
n
FLUID SECTION PARTS LIST
(size)
(size)
Item Description
Qty Part No.
(1) 96379
(2) 94645
(2) 94622
(2) 93581-3
(4) 95092
(2) 94628
(2) 95064
(4) Y327-122
(4) 95727
[Mtl]
[SS]
[GFN]
[SS]
[V]
Item Description
Qty Part No.
(4) 93100-3
(8) 94628
[Mtl]
[V]
(3/4” o.d.)
1
5
6
7
Connecting Rod
Diaphragm Washer
Diaphragm Washer
Diaphragm
22 Ball
o
n
(5/16” - 18 x 3/4”)
26 Flange Bolt
[SS]
[SS]
[SS]
- - -
(5/16” - 18 x 1-1/4”)
27 Bolt
(16) Y84-502-T
(16) 93886
(1) 66885-1
(1) 95065-1
(1) 95066-1
(1) 96333
(5/16” - 18)
29 Hex Flange Nut
57 Ground Kit Assembly
60 Inlet Manifold
61 Outlet Manifold
81 Relief Valve
n
(not shown)
12 Washer
[A]
(5/16” - 18 x 3/4”)
14 Flange Bolt
15 Fluid Cap
[SS]
[A]
[A]
[A]
(3/32” x 1-5/16” o.d.)
19 “O” Ring
21 Seat
[V]
[Br]
n
[A]
“Smart Parts”, keep these items on hand in addition to the service kit for fast repair and reduction of down time.
o
MATERIAL CODE
[A]
=
=
=
=
=
Aluminum
Brass
Glass Filled Nylon
Stainless Steel
Viton
[Br]
[GFN]
[SS]
[V]
TYPICAL CROSS SECTION
Figure 2
Page 4 of 8
670042 (en)
PARTS LIST / 670042 FLUID SECTION
COLOR CODE
Diaphragm
Ball
FOR THE AIR MO-
Material
Color
Color
TOR SECTION, SEE
d
Viton
Yellow (•) Yellow (•)
PAGES 6 & 7.
(•) Dot
81
61
e
26
(
e
c
f
27
1
5
7
6
14
(
22
12
21
c
19
e
29
15
(
e
26
60
22
12
21
19
(
c
Figure 3
ASSEMBLY TORQUE REQUIREMENTS
)
(
NOTE: DO NOT OVERTIGHTEN FASTENERS.
3
1
4
(14) bolt, 95 - 105 in. lbs (10.7 - 11.9 Nm).
(26) bolt, 50 - 60 in. lbs (5.6 - 6.8 Nm), / alternately and evenly, then re-torque after initial run-in.
(29) nut, 50 - 60 in. lbs (5.6 - 6.8 Nm), / alternately and evenly, then re-torque after initial run-in.
5
7
8
6
LUBRICATION / SEALANTS
Apply Lubriplate FML-2 grease (94276) to all “O” rings, “U” cups and mating parts.
Apply gasolene-resistant pipe sealant to threads.
c
d
e
Apply anti-seize compound to threads and bolt and nut flange heads which contact pump
case when using stainless steel fasteners.
2
Apply Loctite® 242® to threads.
f
NOTE: Lubriplate FML-2 is a white food grade petroleum grease.
Torque Sequence
670042 (en)
Page 5 of 8
PARTS LIST / 670042 AIR MOTOR SECTION
Indicates parts included in 637428 air section repair kit.
p
AIR MOTOR PARTS LIST
(size)
(size)
Item
Description
Qty Part No.
(1) 95978
(1) 96091
(1) 96351
(1) 95919
(2) 97111
(2) 96092
(8) 96093
(1) 95979
(1) 96632
(1) 96214-1
(4) 94871
(1) 95980
(1) 95982
(2) Y325-29
(1) 94395
(1) 96383
(1) 93276
[Mtl]
Item
141 Valve Plate
144 “U” Cup Packing
Description
Qty Part No.
(1) 96173
[Mtl]
[Ck]
[B]
101 Center Body
[A]
(right side)
(3/16” x 1” o.d.)
(includes 168 and 169)
103R Cover
103L Cover
[D]
[D]
[D]
[SS]
[D]
[SS]
[A]
(2) Y187-48
(1) 67382
np
p
(left side)
167 Pilot Piston
[D]
[U]
[U]
[D]
[B]
(1/16” x 7/16” o.d.)
111 Major Valve Spool
118 Actuator Pin
121 Washer
168 “O” Ring
(2) 96459
(1/8" x 5/8" o.d.)
169 “U” Cup Packing
170 Spool Bushing
(1) 96384
(1) 96090
p
(#4 - 20 x 1/2”)
(1/16” x 13/16” o.d.)
123 Screw
171 “O” Ring
173 “O” Ring
174 “O” Ring
(2) Y325-17
(2) Y325-115
(2) Y325-105
(1) 96364
p
p
(3/32” x 7/8” o.d.)
(3/32” x 11/32” o.d.)
129 Exhaust Cover
130 Gasket
[B]
[B]
[B]
np
p
132 Air Manifold Gasket
[B]
200 Porting Gasket
201 Muffler
[B]
p
(1/4” - 20 x 5-3/4”)
134 Flange Bolt
135 Valve Block
136 Plug, Large
[SS]
[Z]
(1) 93110
[C]
(1/16” x 3/8” o.d.)
232 “O” Ring
(4) Y325-10
[B]
p
(1/4” - 14 x 1/2”)
[A]
250 Screw
(1) Y334-104-C [C]
(1/16” x 1-5/8” o.d.)
137 “O” Ring
[B]
p
p
p
(1/8” x 1” o.d.)
138 “U” Cup Packing
139 “U” Cup Packing
140 Valve Insert
[U]
[U]
[Ck]
Lubriplate FML-2 Grease
(1) 94276
637308
n p
(1/8” x 1-7/16” o.d.)
Lubriplate Grease Packets (10)
Items included in fluid section service kit, see page 4.
n
MATERIAL CODE
MAJOR VALVE DISASSEMBLY
[A]
[B]
[C]
[Ck]
=
=
=
=
Aluminum
Nitrile
Carbon Steel
Ceramic
[D]
[SS]
[U]
[Z]
=
=
=
=
Acetal
1. Unthread (134) bolts, releasing (129) exhaust cover.
2. Pull (135) valve block and components from (101) center body.
3. Remove (132) gasket, (141) valve plate and (140) valve insert
from (135) valve block.
Stainless Steel
Polyurethane
Zinc
AIR MOTOR SECTION SERVICE
4. Remove (134) bolts, releasing (136) plug and (111) spool.
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.
y
MAJOR VALVE REASSEMBLY
Air Motor Section service is continued from Fluid Section repair.
1. Assemble new (138 and 139) “U” cups on (111) spool - LIPS
PILOT VALVE DISASSEMBLY
MUST FACE EACH OTHER.
2. Assemble (137) “O”rings to (136) large plug.
3. Insert (111) spool into (136) large plug, then insert (136) large
plug into (135) valve block, being sure the (111) spool is rotated
to accept (140) valve insert.
4. Assemble (140) valve insert and (141) valve plate to (135) valve
block. NOTE: Assemble (140) valve insert with “dished” side
toward (141) valve plate. Assemble (141) valve plate with iden-
tification dot toward (132) gasket.
5. Assemble (132 and 200) gaskets, (135) valve block, (130) gasket
and (129) exhaust cover to (101) center body, securing with
(134) bolts. NOTE: Tighten (134) bolts to 15 - 20 in. lbs (1.7 - 2.3
Nm).
1. Remove (123) screws, releasing (103) covers, (121) washers,
(118) actuator pins and (167) pilot piston.
2. Remove (170) spool bushing and inspect inner bore of bushing
for damage.
PILOT VALVE REASSEMBLY
1. Clean and lubricate parts not being replaced from service kit.
2. Assemble (171) “O” rings to (170) bushing and assemble bush-
ing into (101) center body.
3. Lubricate and assemble (167) pilot piston assembly into (170)
bushing.
4. Assemble (173 and 174) “O” rings and (121) washers to (103)
covers, then insert (118) actuator pins through assembly.
5. Assemble (144) “U” cups (note the lip direction) and (103) cov-
ers to (101) center body, securing with (123) screws. NOTE:
Tighten (123) screws to 10 - 12 in. lbs (1.13 - 1.36 Nm).
Page 6 of 8
670042 (en)
PARTS LIST / 670042 AIR MOTOR SECTION
PILOT VALVE PARTS
c
c
c
c
144 118 169
168
171
123
)
103L
c
173
c
232
130
129
201
c
174 121 167 170
140
132
c
144
135
134
138
103R
123
)
(
c
c
c
c
c
141
200
250 101
118 121 174
173
c
c
139
137
111
136
PILOT VALVE PARTS
MAJOR VALVE
) ASSEMBLY TORQUE REQUIREMENTS (
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(123) screw, 10 - 12 in. lbs (1.13 - 1.36 Nm).
(134) bolt, 15 - 20 in. lbs (1.7 - 2.3 Nm), wait 10 minutes, then re-
torque to 15 - 20 in. lbs (0.45 - 0.68 Nm).
Figure 4
LUBRICATION / SEALANTS
c
Apply Lubriplate FML-2 grease to all “O” rings, “U” cups and
mating parts.
670042 (en)
Page 7 of 8
TROUBLE SHOOTING
Product discharged from air exhaust.
y
y
Low output volume.
Check for diaphragm rupture.
Check tightness of (14) bolt.
Check air supply.
y
y
y
Check for plugged outlet hose.
For the pump to prime itself, it must be mounted in the vertical
position so that the balls will check by gravity.
Check 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 non-collapsible type, capable of pulling a high
vacuum.
Air bubbles in product discharge.
Check connections of suction plumbing.
Check “O”rings between intake manifold and fluid caps.
Check tightness of (14) bolt.
y
y
y
y
Pump blows air out main exhaust when stalled on either stroke.
Check “U”cups on (111) spool in major valve.
Check (141) valve plate and (140) insert for wear.
Check (169) “U”cup on (167) pilot piston.
Check all joints on the intake manifolds and suction connec-
tions. These must be air tight.
Inspect the pump for solid objects lodged in the diaphragm
chamber or the seat area.
y
y
y
y
y
DIMENSIONAL DATA
Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
T (air inlet)
A
(Outlet) P
Q
E
L
F
G
N
B
D
K
R
S
M
H
C
J
(Inlet) P
DIMENSIONS
A - 8-7/32”(208.5 mm)
B - 11-1/16”(280.4 mm)
C - 6-1/8”(155.5 mm)
D - 2”(50.8 mm)
F
- 6”(152.4 mm)
L
- 4-5/16” (109.3 mm)
R - 3-1/16”(77.8 mm)
G - 11-3/4” (297.9 mm)
H - 4-7/8” (123.8 mm)
M - 3/8” (9.5 mm)
S
T
- 1-1/4”(31.8 mm)
- 1/4 - 18 N.P.T.F. - 1
N - 6-5/16”(159.9 mm)
P - 1/2 - 14 N.P.T.F. - 1
Q - 8-1/8”(206.0 mm)
J
- 5-1/2”(139.6 mm)
E
- 8-3/16”(207.9 mm)
K - 5/16” (7.9 mm)
Figure 5
PN 97999-1196
670042 (en)
Page 8 of 8
|