Ingersoll Rand Marine Sanitation System 612041 X User Manual

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  
 
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  
 
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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