Ingersoll-Rand 6546X-X, ARO 65440, ARO 65442-B, ARO 65444-2-B, ARO 65462 Operator's Manual

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Page 1

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-



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



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



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

650XXX-X Pump Model Operator’s Manual.



General Information for Air Operated or Hydraulically



Lower Pump End Operator’s Manual.



Air or Hydraulic Motor Operator’s Manual.



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



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



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



Page 2

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

Item Description



1 Screw



2 De ector



3 Screw



4 Screw



5 Washer (4) 90084





6 Screw

7 Washer



8 Air Motor Cap (1) 90078



9 Valve Guide (1) 90093

10 Gasket (1) 90083-1



11 Insert (1) 90097







12 Valve Plate and Pin Assembly (1) 65028

12a Roll Pin



13 Insert Spring Assembly (1) 65032

14 Valve Insert (1) 90796



15 Gasket (1) 90091



16 “O” Ring



17 Washer (1) 91344



18 “O” Ring



19 Head Assembly (1) 65889

20 “U” Cup



21 “O” Ring



22 Screw





24 Piston Assembly (1) 61851



27 Rod Assembly



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

for fast repair and reduction of downtime.



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)

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.)

Page 2 of 8 6544X-X (en)

(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) - - - - -

4 Screws (4)

5 Washers (4)

Figure 2

Item Description



28 Cylinder

29 Tube

30 Base and Bearing Ass’y

31 Valve Piston (1) 92394



32 Washer (1) 90105





33 Gland (1) 91006

34 Seal (1) 91007



35 “O” Ring





36 Extension Rod (1) 90080

38 Adapter (1) 92393





39 Gland (1) 90114

40 Washer (1) 91345



41 “O” Ring



42 Bolt



43 Snap Ring



44 Washer



45 “U” Cup



46 Washer

47 Nut



48 Piston Rod



49 “O” Ring

50 Ground Lug (1) 93006

51 Ground Label

Items included in Service Kit 61268



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

(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

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

Page 3

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



Part numbers listed below and on parts list (opposite







page) are typical.

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

LUBRICATION / SEALANTS

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



36460).

Apply Loctite® 271 to threads.





12a





 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 



Figure 3

6544X-X (en) Page 3 of 8

Figure 4

Page 4

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



AIR MOTOR MODEL NO.



Item Description



Rod Assembly 90107-1

(size)

Part No. (Qty)

Rod Assembly 90107-2



Cylinder 90090-1

Cylinder 90090-2 Tube 79008

Tube 90101-1 Tube 90101-2 Tube 94988 Base and Bearing

Base and Bearing

(Stub)



65020

65023 Base and Bearing 65023-2 Base and Bearing 65025 Base and Bearing Base and Bearing Base and Bearing

(1/2” - 20 x 10-1/4”)

Bolt

(1/2” - 20 x 8-1/4”)

Bolt



43 Snap Ring



44 Washer 73986



45 U” Cup





46 Washer 90103

47 Nut





(1/2” - 20)

(see page 8)

Rod

(see page 8)

Rod

(see page 8)

Rod

(see page 8)

Rod

(see page 8)

Rod

(see page 8)

Rod

(see page 8)

Rod

(see page 8)

Rod

(see page 8)

Rod O” Ring O” Ring

(1/4” x 1-1/4” o.d.)

(1/8” x 1” o.d.)

(1/8” x 1-5/8” o.d.)

52 Pipe Plug

Items included in Service Kit 61268



Indicates where parts are used.





Indicates models no longer active, shown for reference only.



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

(Stub)

(1.456” o.d.)

(1/8” - 27 N.P.T.)

65775

65775-2

90074

94046-1 (4)

94046-2 (4)

Y147-131

Y186-16

Y11-8-C (4)

61776

90082

90108-1

65911-2

90573

90595

66628

93289

93964

Y325-210

Y325-220

Y17-10-C

for fast repair and reduction of downtime.

See model plate on (30) base for number.

On model 65440 and 65462 air motors, a plate is mounted on the bot-



tom of the (30) base. Therefore, the following parts are different and

illustrated on page 8. 93310 Bushing 93311 Retainer 93312 Guide 93313 Plate (note the orientation of the plate with the air inlet) 93958 Plate (note the orientation of the plate with the air inlet) Y6-66-C Screw (4 req’d) Y14-616-C Lock Washer (4 req’d)

NOTE: Base styles and lower packings may vary from that shown on the cover. Refer to model number in the chart above.

61777 65420-1 65440

For simplification of ordering and stocking, a Y325-210 “O” ring, Y325-220 “O” ring and a Y186-16 “U” cup will be included in 61268 service kit. When repairing the motor, use only the one that is needed.

All of the service parts are the same for all motors except the lower piston rod packing.

NOTE: It is highly recommended that a 90350 installation tool be used. This will greatly ease installation of (38) adapter and piston valve and will reduce the chances of damage to the (20) “U” cup. A damaged (20) “U” cup can usually lead to air motor failure.

65441-B

65442-B

65443-B 65443-2B 65444-B

65444-1B 65444-2-B

90350 INSTALLATION TOOL

65445-B

65462

65465-B

65465-1B 65466

Page 4 of 8 6544X-X (en)

Page 5

PARTS LIST / 6544X-X & 6546X-X - (AIR MOTOR PISTON ROD AND BASE)

See chart on the opposite page for each model.

TORQUE REQUIREMENTS



NOTE: DO NOT OVERTIGHTEN FASTENERS.

Tighten (48) rod to 50 - 60 ft lbs. (67.8 - 81.3 Nm).



LUBRICATION / SEALANTS

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



36460).



DISASSEMBLY OF AIR MOTOR (CONT’D)

Remove (21) “O” ring from (19) head assembly.

22. Remove four (22) screws from (39) gland, permitting

23. gland to be removed from (19) head assembly. Remove (16 and 41) “O” rings from (39) gland.

24. Remove (29) tube assembly from (30) base.

25. Remove two (18) “O” rings from (29) tube.

26. Remove (28) cylinder from (30) base. Usually during this

27. step, the (24) piston and (48) piston rod will remain in (28) cylinder. From (30) base assembly (there are 2 types):

28. Type 1 (see  gure 5, above): Remove (43) snap ring, (44) washer, (45) “U” cup and (46) washer. Type 2 (see  gure 11, page 8): Remove (49) “O” ring.

45 

18 



Figure 5

Remove (21) “O” ring from (30) base assembly.

29. Separate (48) piston rod and (24) piston assembly from

30. (28) cylinder. Unscrew (36) extension rod from (27) rod assembly by

31. holding (27) rod assembly with adjustable type pliers and placing a wrench on the provided wrench flats at the top of (36) extension rod. Unscrew (48) piston rod from (24) piston assembly. Use

32. provided wrench  ats on (48) piston rod. Next, remove (27) rod assembly from (48) piston rod.

NOTE: Caution should be exercised so as not to mar or damage the finish on (36) extension rod or (48) piston rod.

6544X-X (en) Page 5 of 8

Page 6

REASSEMBLY OF AIR MOTOR

Apply grease to all “O” rings, “U” cups and other rubber

1. goods before installing. Clean the threads on (27) rod assembly and put the

2. threaded end thru (24) piston assembly. Hold (27) rod assembly below threads with locking type

3. pliers. After applying Loctite 271 to the threads, attach (36) extension rod and draw up tight, using the wrench  ats provided on (36) extension rod. NOTE: Do not mar or damage the surface of (36) extension rod. Place the “machined shoulder” end of (27) rod assembly

4. into the hole in the end of (48) piston rod. After applying Loctite 271 to threads, secure (48) piston rod into (24) piston assembly and tighten to 50 - 60 ft lbs. (67.8 -

81.3 Nm), using provided wrench  ats on (48) piston rod. NOTE: Do not mar or damage the surface of (48) piston rod. Install (21) “O” ring on (30) base assembly.

5. On type one (30) base assembly (see figure 5, page 5),

6. install (46) washer, (45) “U” cup (lips up), (44) washer and (43) snap ring. On type two (30) base assembly (see  gure 11, page 8), install (49) “O” ring. Push (48) piston rod thru (30) base assembly, being care-

7. ful not to damage the lips of (45) “U” cup or (49) “O” ring. Grease the inside of (28) cylinder and fill the area be-

8. tween the lips of (24) piston assembly with grease, then place (28) cylinder over (24) piston and rod assembly (see  gure 6 below). Push (24) piston assembly to the top of (28) cylinder.

9. Install two (18) “O” rings on (29) tube and insert (29) tube

10. assembly into provided hole of (30) base assembly. Install (16 and 41) “O” rings on (39) gland.

11. Grease the bore in (19) head assembly and insert (39)

12. gland assembly into bore of (19) head assembly with a twisting motion.

15. Push (36) extension rod thru (41) “O” ring in the base of (19) head assembly.

16. Press (19) head assembly down, seating against (28) cylinder and (29) tube assembly.

17. Insert four (42) bolts down thru the holes in the  ange of (19) head assembly and (30) base assembly.

18. Screw four (47) nuts on (42) bolts. Alternately and evenly tighten four (47) nuts.

19. Install (20) “U” cup in (38) adapter, with the lips down toward the thick  ange of (38) adapter.

20. Install (35 and 16) “O” rings in the (33) gland.

21. Bend (34) seal in a heart shape (see  gure 7 below) and install in (33) gland, next to (35) “O” ring (see  gure 8 below).

Seal free form Seal collapsed form

Push sides in, as shown, then slide into bore and position seal in groove.

Figure 7

22. Carefully push (31) valve piston into (33) gland to size (34) seal (see  gure 9 below). After sizing, remove (31) valve piston from (33) gland.

16 - “O” Ring

35 - “O” Ring

34 - Seal

Direction for sizing

28 Cylinder (apply grease

13. Align holes in (39) gland and (19) head assembly and secure with four (22) screws.

14. Install (21) “O” ring on (19) head assembly.

Page 6 of 8 6544X-X (en)

throughout inside)

Apply grease

48 Piston Rod

Figure 6

31 - Valve Piston

Figure 8

33 - Gland

23. Slide (40) washer over (36) extension rod.

24. Pull (36) extension rod up and grasp with two  ngers (see  gure 9 below).

32 Washer

groove

36 Extension Rod

Figure 9

25. Place 90350 special installation tool over (36) extension rod, with turned diameter down and the chamber side up.

(continued on page 7)

Page 7

REASSEMBLY OF AIR MOTOR (CONT’D)

26. Fit the turned diameter of the 90350 special installation tool into the bore in the bottom of (19) head assembly.

27. Place (38) adapter assembly down over (36) extension rod, with the thread on the (38) adapter up.

28. Insert (32) washer into the groove on the top of (36) extension rod.

29. Pull (38) adapter up around the (32) washer.

30. Place (17) washer over (36) extension rod and onto (38) adapter.

31. Clean with solvent and put Loctite 271 on the threads of (38) adapter. Screw (31) valve piston onto (38) adapter and tighten (see  gure 4, page 3).

32. Push the assembled (38) adapter and (31) valve piston down thru the 90350 special installation tool until it bottoms.

33. Remove the 90350 special installation tool by pulling up on it.

34. Install (33) gland assembly over the (31) valve piston and push down, being careful to retain (34) seal in the “O” ring groove.

35. Align the two screw holes and secure (33) gland assembly to (19) head assembly with two (6) screws and two (7) lock washers.

36. Insert (13) insert spring assembly into the (19) head assembly, with the hooks down and the nylon roller toward (31) valve piston.

37. Apply grease to both (11 and 14) inserts and place them in position (see  gure 10) with legs of insert toward (31) valve piston and the larger, (14) insert, located in front of the larger diameter nylon roller. Also, the nylon roller on the (13) insert spring assembly should be between the legs of both (11 and 14) inserts.

38. Apply grease to gasket side of (12) valve plate and put (15) gasket on (12) valve plate. To determine the correct side, the screw holes nearest the top and bottom of (12) valve plate are toward the exhaust port on the (19) head assembly. Also, the (12a) roll pins in (12) valve plate are at the top.

39. Hold the (11 and 14) inserts against the (31) valve piston

and slide the (15) gasket and (12) valve plate between the two inserts and (19) head assembly. Be sure the larger holes in the (12) valve plate are located in front of the larger or (14) insert. Also, be sure the pins are located at the top of the valve plate.

40. Hook the round coil in (13) insert spring assembly over the (12a) roll pins (see  gure 10).

41. Hook the bottoms of the (13) insert spring assembly into the holes on the side of (12) valve plate (see  gure 10).

42. Insert (9) valve guide against the face of (12) valve plate. The legs of (9) valve guide should be down, with the leg having the threaded hole nearest the bottom located nearest the exhaust port of the (19) head assembly.

43. Place (5) washer on each of the four (4) screws and insert into the provided holes and tighten evenly across the corners. NOTE: To ease the alignment of the holes, an “O” ring pick is helpful.

44. Install (10) gasket in (8) air motor cap and secure with six (3) screws.

45. Place (2) de ector on the exhaust port of (19) head assembly, with the opening down, and secure with four (1) screws.

11 - Insert

9 - Valve Guide

12 - Valve Plate and

Pin Assembly

12a - Roll Pin

14 - Valve Insert

13 - Insert Spring

Assembly

4 - Screw (4) 5 - Washer (4)

Figure 10

Air leakage out of main exhaust.

Worn (14) insert. Replace (14) insert.



Worn (12) valve plate and pin assembly. Replace (12)



valve plate and pin assembly. Damaged (24) piston assembly. Replace (24) piston as-



sembly.

6544X-X (en) Page 7 of 8

TROUBLE SHOOTING

Continual air leakage out of bleeder hole in (19) head assembly.

Worn (35) “O” ring or (34) seal. Replace (35) “O” ring and



(34) seal.

Air leakage around (48) piston rod.

Worn (45) “U” cup. Replace (45) “U” cup.



Page 8

65440 AND 65462 AIR MOTOR PISTON ROD AND BASE

Piston Rod

(see item 48, page 4)

65020 Base and Bearing

Assembly (stub)

93312 Guide

Figure 11

Y325-210 “O” R ing

93310 Bushing

93311 Retainer

Y6-66-C Screw (4 req’d)

Y14-616-C Lock

Washer (4 req’d)

93958 Plate (used on 65440 air motor)

93313 Plate (used on 65462 air motor)

ITEM 48 PISTON ROD END VARIETY

65911-2 Piston Rod 90108-1 Piston Rod

Figure 12

Page 8 of 8 6544X-X (en)

90573 Piston Rod 93964 Piston Rod

61776 Piston Rod 66628 Piston Rod 90595 Piston Rod

90082 Piston Rod 93289 Piston Rod

PN 97999-64