Ingersoll Rand Automobile Parts 670042 User Manual

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 . . . . . . . . . . . . . . . . 3/32dia. (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)  
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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.  
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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  
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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.  
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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.  
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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  
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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 “Orings and seals in the air motor section of the pump.  
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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.  
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Tools needed to complete disassembly and repair:  
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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.  
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IMPORTANT  
Requirements for the installation are included in the Flam-  
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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) “Orings, (21) seats, (12) washers and (22) balls.  
3. Remove (60) bottom manifold.  
4. Remove (19) “Orings, (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.  
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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.  
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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.  
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Always flush the pump with a solvent compatible with the ma-  
terial being pumped if the material being pumped is subject to  
“setting upwhen not in use for a period of time.  
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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-  
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Viton® is a registered trademark of the DuPont Company Loctite® and 242® are registered trademarks of Henkel Loctite Corporation  
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Lubriplate® is a registered trademark of Lubriplate Division (Fiske Brothers Refining Company) ARO® is a registered trademark of Ingersoll-Rand Company  
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670042 (en)  
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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).  
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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  
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(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.  
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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)  
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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
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f
27  
1
5
7
6
14  
(
22  
12  
21  
c
19  
e
29  
15  
(
e
26  
60  
22  
12  
21  
19  
(
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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.  
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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.  
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NOTE: Lubriplate FML-2 is a white food grade petroleum grease.  
Torque Sequence  
670042 (en)  
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PARTS LIST / 670042 AIR MOTOR SECTION  
Indicates parts included in 637428 air section repair kit.  
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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.  
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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.  
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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) “Orings 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)  
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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)  
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TROUBLE SHOOTING  
Product discharged from air exhaust.  
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Low output volume.  
Check for diaphragm rupture.  
Check tightness of (14) bolt.  
Check air supply.  
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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 “Orings between intake manifold and fluid caps.  
Check tightness of (14) bolt.  
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Pump blows air out main exhaust when stalled on either stroke.  
Check “Ucups on (111) spool in major valve.  
Check (141) valve plate and (140) insert for wear.  
Check (169) “Ucup 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.  
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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)  
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