OPERATOR’S MANUAL
612041-X
INCLUDING: SPECIFICATIONS, SERVICE KITS, GENERAL INFORMATION, PARTS, TROUBLESHOOTING
INCLUDE MANUAL: S-632 GENERAL INFORMATION (PN 97999-624)
612042-X
RELEASED: 10-23-86
REVISED:
(REV. K)
10-12-11
2” AIR MOTOR
1:1 RATIO
2” DIFFERENTIAL
TRANSFER PUMP
0 - 150 P.S.I. RANGE
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
PUMP DATA
•
Use only genuine AROR replacement parts to assure compatible
pressure rating and longest service life.
MODEL 61204X-X
•
•
•
637084 for air motor repair (see page 2).
48
637081 for lower pump end (Nitrile) repair (see page 3).
637083 for lower pump end (PTFE) repair (see page 3).
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
Air Inlet (female)
1/4 - 18 N.P.T.F. - 1
“A”
Material Outlet (female)
3/4 - 14 N.P.T.F. - 1
Material Outlet (female) . . . . . . . 3/4 - 14 N.P.T.F. - 1
Pump Construction . . . . . . . . . . Carbon Steel
Dimensional Data . . . . . . . . . . . . . See Chart
Weight . . . . . . . . . . . . . . . . . . . . . . See Chart
‘‘B’’
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
Figure 1
Displacement In3 Per Cycle . . . . . . 18.8
Volume / Cycle . . . . . . . . . . . . . . . . 10.4 oz. (307.7 ml)
Cycles Per Gallon . . . . . . . . . . . . . 12.3
Maximum Working Flow Rate . . . . 9 g.p.m. (34.1 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)*
Material Inlet
Immersed
NOTE: Dimensions are shown in inches and (mm), supplied for reference only and are typically
rounded up to the nearest 1/16 inch.
*
ThepumpsoundpressurelevelhasbeenupdatedtoanEquivalentContinuousSound
Level (L ) to meet the intent of ANSI S1. 13-1971, CAGI-PNEUROP S5.1 using four
Aeq
microphone locations.
MODEL
612041-X
612042-X
“A” (mm)
54” (1371.6)
64-1/4” (1631.9)
“B” (mm)
WEIGHT (kg)
13 lb (5.9)
14 lb (6.4)
34-5/8” (879.5)
44-7/8” (1139.8)
GENERAL DESCRIPTION
IMPORTANT
The Aro 2’’ differential 1:1 ratio transfer pumps are 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 other materi-
als which make it compatible with most petroleum based lubrication
products.
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-632 GENERAL INFORMATION LUBRICATION PISTON PUMPS
OPERATING AND SAFETY PRECAUTIONS
WARNING Read the General Information Manual for operat-
ing and safety precautions and important information.
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET – BRYAN, OHIO 43506
CCN 99444598
(800) 495-0276 FAX(800) 892-6276
© 2011
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PARTS LIST / LOWER PUMP SECTION
Item Description (size in inches)
22 Piston Rod
Qty Part No.
(1) 77804
[Mtl]
[C]
23 “O” Ring (1/16” x 5/8” o.d.)
24 Plug
(1) Y325-14
(1) 79057
[B]
20
[NY]
- 25 “O” Ring (3/32” x 2-1/16” o.d.)
models 61204X-1
3/4 N.P.T.F. - 1
(1) Y325-134
(1) Y327-134
[B]
[V]
models 612041-3
- 26 “O” Ring (3/32” x 1-7/16” o.d.)
models 61204X-1
(1) Y325-124
(1) Y327-124
(1) Y122-85
(1) 76900
[B]
[V]
[C]
[C]
[C]
[B]
23
24
22
models 612041-3
27 Groove Pin (1/8” dia. x 3/4”)
28 Collar
29 Washer (models 612041-3 only)
- 30 Packing (models 61204X-1 only)
- 31 “O” Ring (1/16” x 1/2” o.d.)
models 61204X-1
(1) 77910
(2) 75649
(1) Y325-12
(1) Y327-12
(1) 77801
(1) 75648
(1) 77827
(1) 77798
(1) 77814
(1) 77797
(1) 77806
(1) 77796
(1) 77826
(1) 77800
(1) Y115-14
(1) 76093
(1) F58-3
[B]
[V]
[C]
models 612041-3
25
32 Retaining Ring
- 33 Piston models 61204X-1
models 612041-3
[D]
[T]
34
26
34 Suction Tube models 612041-X
models 612042-1
[C]
[C]
[C]
[C]
[B]
[T]
35 Washer
36 Tube
- 37 Cup models 61204X-1
models 612041-3
29
33
38 Washer
[C]
[SS]
[C]
[C]
[CI]
27
28
39 Nut (3/8” - 24)
40 Stem
41 Plate
33
30
42 Valve Body
(1) F259-1
(1) 60657
(1) 60870
(1) Y197-158-C
(1) 92818
43 Foot Valve Asm (includes items 40 - 42)
44 Bung Adapter (includes item 45)
45 Screw (1/4” - 20 x 1-1/2”)
48 Needle Valve (see figure 1)
[C]
[C]
31
32
612041-3
[Br]
36
- Parts included in 637081 service kit (models 61204X-1).
Parts included in 637083 service kit (models 612041-3).
35
37
38
39
41
42
40
43
Figure 5
612041-X
Page 3 of 4
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2. Place the (9) valve plate on top of the (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. Lay this
assembly aside for the moment.
PUMP DISASSEMBLY (continued)
NOTE: Perform steps 8 thru 10 only if (7) spacer and piston assembly
needs servicing.
8. Removethethree(8)screwsfromthe(11)valvespacer(seefigure4).
9. Remove the (9) valve plate.
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. Placethe(18)pumpbodyinaviseandrotateitsothematerialoutlet
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) plunger up and thread (13) plunger tip to plunger and tight-
en by using a wrench on flats of (13) plunger tip and a strap wrench
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) cylinder and 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)
capandassemblecapto(6)cylinder, tighteningusinga strapwrench.
10. Remove the (11) valve spacer from the (10) piston assembly.
11. Unthread(13)plungertipfromthe(15)plungerbyusingawrenchon
the flatsof the(13) plunger tip and a strapwrench on the (15) plung-
er. CAUTION:Placethestrapwrenchontheveryuppermostpartof
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)intakevalveassemblyinavise.Usingastrapwrench
on (34) suction tube, unthread and remove from valve assembly.
CAUTION: Do not damage or dent this tube.
25. Usingawrenchonflatsof(22)pistonrod, unthreadandremove(39)
nut (see figure 4).
26. Remove(38)washer,(37)cupand(35)washerfrom(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.
31. NOTE: Do not remove (27) groove pin and (28) collar from (22) pis-
ton rod unless damage is evident. Remove (27) groove pin, releas-
ing (28) collar.
PUMP REASSEMBLY
1. Insertthe(11)valvespacerthruthebottomofthe(10)pistonassem-
bly (see figure 4).
TROUBLE SHOOTING
Pump continually cycles.
Material on one stroke only (fast upstroke).
•
Checkforemptymaterialsupply.Disconnecttheair(fromthepump)
replenish material supply.
•
Check for worn or damaged (37) cup. Replace cup (see pump
instructions and figure 4).
•
Check for worn or damaged (30) packing or (33) piston.
Material leakage out the top of the pump body.
• Check for worn or damaged (30) packing or (33) piston.
Material on one stroke only (fast downstroke).
•
The intake valve assemblymaynot be checking or sealingproperly.
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,thoroughlycleanandreassembletothepump(seepump
instructions).
Air leakage out of the exhaust holes. (See Air Motor Instructions)
•
Check to see if the (9) valve plate is loose or has become disas-
sembled from the (11) valve spacer.
•
•
•
Check for worn or damaged (10) piston assembly.
Check for worn or warped (9) valve plate.
Worn or damaged (14) “O” ring. Replace (14) “O’’ ring.
PN 97999-93
612041-X
Page 4 of 4
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