Ingersoll-Rand 6546X-X, 6544X-X User Manual

OPERATOR’S MANUAL 6544X-X

INCLUDING: SERVICE KITS, TROUBLESHOOTING, PARTS LIST,

6546X-X

DISASSEMBLY & REASSEMBLY.

4-1/4” AIR MOTORS

6544X-X (4” STROKE) and 6546X-X (6” STROKE)

Also covers 61268 service kits

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.

THIS MANUAL COVERS THE FOLLOWING MODELS

MODEL

65440 65442-B 65444-2-B 65462

65441-B 65444-B 65445-B 65465-B

Also covers obsolete and cancelled models: 61777, 65420-1, 65443-B, 65443-2-B, 65444-1B, 65465-1-B and 65466.

SERVICE KITS

Use only genuine ARO® replacement parts to assure com-

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patible pressure rating and longest service life. 61268 for general repair of all 4-1/4” air motors.

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RELEASED: 2-26-82 REVISED: 11-28-07 (REV. U)

GENERAL DESCRIPTION

WARNING

PRESSURE AS INDICATED ON PUMP MODEL PLATE.

WARNING

FOR ADDITIONAL SAFETY PRECAUTIONS AND IMPORTANT INFORMATION.

This manual only covers the air motor section. It is one of

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four documents which support an ARO pump. Replacement copies of these forms are available upon request.

650XXX-X Pump Model Operator’s Manual.

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General Information for Air Operated or Hydraulically

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Lower Pump End Operator’s Manual.

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Air or Hydraulic Motor Operator’s Manual.

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The 4-1/4” air motor is a general purpose power unit and

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is used with many 2-ball, 4-ball and chop check pumps. It utilizes tie rod type construction for easy breakdown and it connects to the various lower ends via tie rods for easy operation. Consult pump model operator’s manual for speci c instructions. It is recommended that a mu er be connected to the exhaust port to reduce noise to acceptable OSHA standards. Filtered and oiled air will allow the air motor to operate

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more e ciently and yield a longer life to operating parts and mechanisms. A filter capable of filtering particles larger than 50 microns should be used with an oiler. Keep the oiler supplied with a good grade of S.A.E. no. 90W non-detergent gear oil, set at a rate not to exceed 1 or 2 drops per minute.

NOTICE: Do not operate the air motor above the recommended air pressure of 150 p.s.i. (10.3 bar) or 75 cycles per minute. The air motor may be rated di erently in the next assembly. Check the pump model plate.

DO NOT EXCEED MAXIMUM OPERATING

REFER TO GENERAL INFORMATION SHEET

Operated Pumps.

Figure 1

MAINTENANCE

The air / hydraulic motor is completely separate from the lower pump end. This helps to keep the motor from being contaminated by the material being pumped. Periodically,  ush entire pump system with a solvent that is compatible with the material being pumped. Keep solvent cup  lled with this compatible solvent. This will keep material from drying on the piston rod, which would drag thru the packings, ruin them and eventually scour the piston rod. Provide a clean work surface to protect sensitive internal moving parts from contamination from dirt and foreign matter during disassembly and reassembly. Before reassembling, lubricate parts as required. When assembling “O” rings, or parts adjacent to “O” rings, exercise care to prevent damage to “O” rings and “O” ring groove surface.

INGERSOLL RAND COMPANY LTD

P.O. BOX 151  ONE ARO CENTER  BRYAN, OHIO 43506-0151

(800) 276-4658  FAX (800) 266-7016

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PARTS LIST / 6544X-X & 6546X-X

Item Description

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1 Screw

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2 De ector

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3 Screw

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4 Screw

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5 Washer (4) 90084

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6 Screw

7 Washer

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8 Air Motor Cap (1) 90078

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9 Valve Guide (1) 90093

10 Gasket (1) 90083-1

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11 Insert (1) 90097

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12 Valve Plate and Pin Assembly (1) 65028

12a Roll Pin

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13 Insert Spring Assembly (1) 65032

14 Valve Insert (1) 90796

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15 Gasket (1) 90091

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16 “O” Ring

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17 Washer (1) 91344

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18 “O” Ring

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19 Head Assembly (1) 65889

20 “U” Cup

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21 “O” Ring

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22 Screw

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24 Piston Assembly (1) 61851

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27 Rod Assembly

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“Smart Parts”, keep these items on hand in addition to the service kits

for fast repair and reduction of downtime.

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Includes item (12a) roll pin (qty 2).

(size)

(#8 - 32 x 7/8”) (not shown)

(not shown)

(#10 - 24 x 1/2”)

(#8 - 32 x 3/4”)

(1/4” - 28 x 3/4”)

(1/4” i.d.)

(3/32” o.d. x 3/4” long)

(1/16” x 1-3/8” o.d.)

(1/16” x 3/4” o.d.)

(3/16” x 1-3/8” o.d.)

(1/8” x 4-1/4” o.d.)

(#8 - 32 x 3/8”)

(see chart, page 4)

(Qty) Part No.

(4) Y136-90-S

(1) 90409

(6) 95956827

(4) Y19-89-S

(2) Y119-49-C

(2) Y14-416

(2) Y178-26-S

(2) Y325-26

(2) Y325-16

(1) Y186-51

(2) Y325-242

(4) Y136-85-S

(1) - - - - -

DISASSEMBLY OF AIR MOTOR

NOTE: All threads are right hand.

Place motor in up stroke position. This can be accom-

1. plished by pushing (48) rod toward the top of the air motor. Remove four (1) screws from (2) de ector.

2. Remove (2) de ector.

3. Remove six (3) screws from (8) air motor cap.

4. Remove (8) air motor cap and (10) gasket.

5. Loosen four (4) screws (which hold (12) valve plate and

6. (9) valve guide) until (9) valve guide can be removed by pulling upward (see  gure 9, page 6).

Allen Wrench

(Use an Allen wrench to push out screws and washers as shown.)

Item Description

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28 Cylinder

29 Tube

30 Base and Bearing Ass’y

31 Valve Piston (1) 92394

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32 Washer (1) 90105

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33 Gland (1) 91006

34 Seal (1) 91007

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35 “O” Ring

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36 Extension Rod (1) 90080

38 Adapter (1) 92393

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39 Gland (1) 90114

40 Washer (1) 91345

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41 “O” Ring

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42 Bolt

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43 Snap Ring

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44 Washer

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45 “U” Cup

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46 Washer

47 Nut

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48 Piston Rod

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49 “O” Ring

50 Ground Lug (1) 93006

51 Ground Label

Items included in Service Kit 61268

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Remove four (4) screws and four (5) washers from (19)

7. head assembly by pressing outward with a small allen wrench, as illustrated in  gure 2. With the aid of a screwdriver, unhook the legs of (13) in-

8. sert spring assembly from the bottom of (12) valve plate. Remove (12) valve plate and (13) insert spring assembly

9. from (19) head by pulling upward. If (12) valve plate is stuck, tap the top edge lightly with a soft face mallet. Do not tap with anything metallic. Remove both (11 and 14) inserts and (13) insert spring

10. assembly from (12) valve plate. Remove (15) gasket from (19) head assembly.

11. Remove two (6) screws and two (7) lock washers from

12. (33) gland in (19) head assembly. With fingers, pull (31) valve piston upward until (33)

13. gland has pulled out of its chamber. Remove (33) gland by sliding it up over (31) valve piston.

14. Remove (34) seal and (35) “O” ring from (33) gland (see

15.  gure 8, page 6). Disassemble (31) valve piston from (38) adapter as

16. shown in  gure 4, page 3. Pull (38) adapter upward until assembly is taut and

17. grasp (36) extension rod with  ngers, as shown in  gure

(size)

(see chart, page 4)

(0.103” x 1.255” o.d.)

(1/16” x 7/16” o.d.)

(see chart, page 4)

(not shown)

(see chart, page 4)

(Qty) Part No.

(1) - - - - -

(1) 91207

(1) Y325-11

(4) - - - - -

(1) - - - - -

(4) - - - - -

(1) - - - - -

(1) 93007

9, page 6. Grasp (36) extension rod below (38) adapter.

4 Screws (4)

5 Washers (4)

Figure 2

Page 2 of 8 6544X-X (en)

Now push (38) adapter down on (36) extension rod and remove (32) washer from (36) extension rod. Now remove (38) adapter. Remove (17) washer and (20) “U” cup from (38) adapter.

18. Remove four (47) nuts from four (42) bolts.

19. Remove four (42) bolts.

20. Remove (19) head assembly and place on the work-

21. bench with (8) cap side down. This action will allow (40) washer to fall out of its cavity.

(continued on page 5)

PARTS LIST / 6544X-X & 6546X-X - (AIR MOTOR HEAD)

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Part numbers listed below and on parts list (opposite

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page) are typical.

NOT SHOWN 93897-1 Pipe Plug (models 65440 only)

LUBRICATION / SEALANTS

NOTE: Lubricate with Parker “O” ring lube (ARO p/n

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36460).

Apply Loctite® 271 to threads.

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12a

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 271™ is a trademark of Henkel Loctite Corporation   ARO® is a registered trademark of Ingersoll Rand Company   Loctite®is a registered trademark of Henkel Loctite Corporation 

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Figure 3

Figure 4

6544X-X (en) Page 3 of 8

+ 5 hidden pages