OPERATOR’S MANUAL
6544X-X
6546X-X
INCLUDING: SERVICE KITS, TROUBLESHOOTING, PARTS LIST,
DISASSEMBLY & REASSEMBLY.
RELEASED:
REVISED:
(REV. U)
2-26-82
11-28-07
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
65441-B
65442-B
65444-B
65444-2-B
65445-B
65462
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.
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GENERAL DESCRIPTION
WARNING DO NOT EXCEED MAXIMUM OPERATING
PRESSURE AS INDICATED ON PUMP MODEL PLATE.
WARNING REFER TO GENERAL INFORMATION SHEET
FOR ADDITIONAL SAFETY PRECAUTIONS AND IMPOR-
TANT INFORMATION.
This manual only covers the air motor section. It is one of
four documents which support an ARO pump. Replace-
ment copies of these forms are available upon request.
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650XXX-X Pump Model Operator’s Manual.
General Information for Air Operated or Hydraulically
Operated Pumps.
Lower Pump End Operator’s Manual.
Air or Hydraulic Motor Operator’s Manual.
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Figure 1
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ꢃ
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
specific instructions. It is recommended that a muffler be
connected to the exhaust port to reduce noise to accept-
able OSHA standards.
Filtered and oiled air will allow the air motor to operate
more efficiently 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.
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,
flush entire pump system with a solvent that is compatible
with the material being pumped.
Keep solvent cup filled 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 mat-
ter during disassembly and reassembly.
Before reassembling, lubricate parts as required. When as-
sembling “O” rings, or parts adjacent to “O” rings, exercise
care to prevent damage to “O” rings and “O” ring groove sur-
face.
NOTICE: Do not operate the air motor above the recom-
mended air pressure of 150 p.s.i. (10.3 bar) or 75 cycles
per minute. The air motor may be rated differently in the
next assembly. Check the pump model plate.
INGERSOLL RAND COMPANY LTD
P.O. BOX 151 ONE ARO CENTER BRYAN, OHIO 43506-0151
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© 2007
CCN 81582769
(800) 276-4658 FAX (800) 266-7016
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PARTS LIST / 6544X-X & 6546X-X - (AIR MOTOR HEAD)
Part numbers listed below and on parts list (opposite
page) are typical.
50
6
7
4
5
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NOT SHOWN
93897-1 Pipe Plug (models 65440 only)
LUBRICATION / SEALANTS
3
NOTE: Lubricate with Parker “O” ring lube (ARO p/n
36460).
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Apply Loctite® 271 to threads.
8
9
11
31
32
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33
34
35
36
38
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40
16
39
41
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10
ꢀ
12a
12
13
14
15
16
17
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18
19
20
21
22
24
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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 ꢀ
Figure 3
31
38
Figure 4
6544X-X (en)
Page 3 of 8
PARTS LIST / 6544X-X & 6546X-X
¾
AIR MOTOR MODEL NO.
(size)
Item Description
Part No.
90107-1
90107-2
90090-1
90090-2
79008
(Qty)
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Rod Assembly
Rod Assembly
Cylinder
27
28
29
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Cylinder
Tube
Tube
Tube
Tube
90101-1
90101-2
94988
(Stub)
(Stub)
Base and Bearing
Base and Bearing
Base and Bearing
Base and Bearing
Base and Bearing
Base and Bearing
Base and Bearing
65020
65023
65023-2
65025
65775
65775-2
90074
94046-1
94046-2
Y147-131
73986
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30
42
(Stub)
(Stub)
(Stub)
(1/2” - 20 x 10-1/4”)
(1/2” - 20 x 8-1/4”)
(1.456” o.d.)
Bolt
Bolt
(4)
(4)
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43 Snap Ring
44 Washer
(1/4” x 1-1/4” o.d.)
45 U” Cup
Y186-16
90103
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46 Washer
(1/2” - 20)
47 Nut
Y11-8-C
61776
90082
90108-1
65911-2
90573
90595
66628
93289
93964
(4)
(see page 8)
(see page 8)
(see page 8)
(see page 8)
(see page 8)
(see page 8)
(see page 8)
(see page 8)
(see page 8)
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Rod
Rod
Rod
Rod
Rod
Rod
Rod
Rod
Rod
48
(1/8” x 1” o.d.)
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O” Ring
O” Ring
Y325-210
Y325-220
Y17-10-C
61268
49
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(1/8” x 1-5/8” o.d.)
(1/8” - 27 N.P.T.)
52 Pipe Plug
Items included in Service Kit
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Indicates where parts are used.
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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.
Indicates models no longer active, shown for reference only.
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“Smart Parts”, keep these items on hand in addition to the service kits
for fast repair and reduction of downtime.
¾
See model plate on (30) base for number.
All of the service parts are the same for all motors except the
lower piston rod packing.
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.
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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)
90350 INSTALLATION TOOL
Y14-616-C Lock Washer (4 req’d)
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.
NOTE: Base styles and lower packings may vary from that
shown on the cover. Refer to model number in the chart
above.
Page 4 of 8
6544X-X (en)
PARTS LIST / 6544X-X & 6546X-X - (AIR MOTOR PISTON ROD AND BASE)
See chart on the opposite page for each model.
TORQUE REQUIREMENTS
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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).
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27
42
29
52
28
49
21
44
46
47
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43
45 ꢀ
18 ꢀ
30
48
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Figure 5
29. Remove (21) “O”ring from (30) base assembly.
30. Separate (48) piston rod and (24) piston assembly from
(28) cylinder.
31. Unscrew (36) extension rod from (27) rod assembly by
holding (27) rod assembly with adjustable type pliers
and placing a wrench on the provided wrench flats at
the top of (36) extension rod.
32. Unscrew (48) piston rod from (24) piston assembly. Use
provided wrench flats on (48) piston rod. Next, remove
(27) rod assembly from (48) piston rod.
DISASSEMBLY OF AIR MOTOR (CONT’D)
22. Remove (21) “O”ring from (19) head assembly.
23. Remove four (22) screws from (39) gland, permitting
gland to be removed from (19) head assembly.
24. Remove (16 and 41) “O”rings from (39) gland.
25. Remove (29) tube assembly from (30) base.
26. Remove two (18) “O”rings from (29) tube.
27. Remove (28) cylinder from (30) base. Usually during this
step, the (24) piston and (48) piston rod will remain in
(28) cylinder.
NOTE: Caution should be exercised so as not to mar or
damage the finish on (36) extension rod or (48) piston rod.
28. From (30) base assembly (there are 2 types):
Type 1 (see figure 5, above): Remove (43) snap ring, (44)
washer, (45) “U”cup and (46) washer.
Type 2 (see figure 11, page 8): Remove (49) “O”ring.
6544X-X (en)
Page 5 of 8
15. Push (36) extension rod thru (41) “O” ring in the base of
(19) head assembly.
REASSEMBLY OF AIR MOTOR
16. Press (19) head assembly down, seating against (28) cyl-
inder and (29) tube assembly.
17. Insert four (42) bolts down thru the holes in the flange 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 to-
ward the thick flange of (38) adapter.
20. Install (35 and 16) “O”rings in the (33) gland.
21. Bend (34) seal in a heart shape (see figure 7 below) and
install in (33) gland, next to (35) “O” ring (see figure 8 be-
low).
1. Apply grease to all “O” rings, “U” cups and other rubber
goods before installing.
2. Clean the threads on (27) rod assembly and put the
threaded end thru (24) piston assembly.
3. Hold (27) rod assembly below threads with locking type
pliers. After applying Loctite 271 to the threads, attach
(36) extension rod and draw up tight, using the wrench
flats provided on (36) extension rod. NOTE: Do not mar
or damage the surface of (36) extension rod.
4. Place the “machined shoulder” end of (27) rod assembly
into the hole in the end of (48) piston rod. After apply-
ing 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 flats on (48) piston rod.
NOTE: Do not mar or damage the surface of (48) piston
rod.
5. Install (21) “O”ring on (30) base assembly.
6. On type one (30) base assembly (see figure 5, page 5),
install (46) washer, (45) “U” cup (lips up), (44) washer and
(43) snap ring. On type two (30) base assembly (see fig-
ure 11, page 8), install (49) “O”ring.
7. Push (48) piston rod thru (30) base assembly, being care-
ful not to damage the lips of (45) “U”cup or (49) “O”ring.
8. Grease the inside of (28) cylinder and fill the area be-
tween the lips of (24) piston assembly with grease, then
place (28) cylinder over (24) piston and rod assembly (see
figure 6 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 figure 9 below). After sizing, remove (31) valve
piston from (33) gland.
9. Push (24) piston assembly to the top of (28) cylinder.
10. Install two (18) “O” rings on (29) tube and insert (29) tube
assembly into provided hole of (30) base assembly.
11. Install (16 and 41) “O”rings on (39) gland.
12. Grease the bore in (19) head assembly and insert (39)
gland assembly into bore of (19) head assembly with a
twisting motion.
16 - “O” Ring
35 - “O” Ring
34 - Seal
Direction for sizing
31 - Valve Piston
28 Cylinder (apply grease
throughout inside)
33 - Gland
Figure 8
23. Slide (40) washer over (36) extension rod.
24. Pull (36) extension rod up and grasp with two fingers (see
figure 9 below).
Apply grease
48 Piston Rod
36 Extension Rod
32 Washer
groove
Figure 9
Figure 6
25. Place 90350 special installation tool over (36) extension
rod, with turned diameter down and the chamber side
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.
up.
(continued on page 7)
Page 6 of 8
6544X-X (en)
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.
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) ex-
tension 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 figure 4, page 3).
32. Push the assembled (38) adapter and (31) valve piston
down thru the 90350 special installation tool until it bot-
toms.
40. Hook the round coil in (13) insert spring assembly over
the (12a) roll pins (see figure 10).
41. Hook the bottoms of the (13) insert spring assembly into
the holes on the side of (12) valve plate (see figure 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.
33. Remove the 90350 special installation tool by pulling up
on it.
44. Install (10) gasket in (8) air motor cap and secure with six
(3) screws.
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 assem-
bly to (19) head assembly with two (6) screws and two (7)
lock washers.
45. Place (2) deflector on the exhaust port of (19) head as-
sembly, with the opening down, and secure with four (1)
screws.
11 - Insert
36. Insert (13) insert spring assembly into the (19) head
assembly, with the hooks down and the nylon roller to-
ward (31) valve piston.
37. Apply grease to both (11 and 14) inserts and place them
in position (see figure 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.
9 - Valve Guide
12 - Valve Plate and
Pin Assembly
12a - Roll Pin
14 - Valve Insert
13 - Insert Spring
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.
Assembly
4 - Screw (4)
5 - Washer (4)
Figure 10
39. Hold the (11 and 14) inserts against the (31) valve piston
TROUBLE SHOOTING
Air leakage out of main exhaust.
Continual air leakage out of bleeder hole in (19) head as-
sembly.
Worn (14) insert. Replace (14) insert.
Worn (12) valve plate and pin assembly. Replace (12)
valve plate and pin assembly.
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Worn (35) “O” ring or (34) seal. Replace (35) “O” ring and
(34) seal.
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Damaged (24) piston assembly. Replace (24) piston as-
sembly.
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Air leakage around (48) piston rod.
Worn (45) “U”cup. Replace (45) “U”cup.
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6544X-X (en)
Page 7 of 8
65440 AND 65462 AIR MOTOR PISTON ROD AND BASE
Piston Rod
Y325-210 “O” Ring
93310 Bushing
93311 Retainer
(see item 48, page 4)
65020 Base and Bearing
Assembly (stub)
93312 Guide
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)
Figure 11
ITEM 48 PISTON ROD END VARIETY
65911-2 Piston Rod
90108-1 Piston Rod
90573 Piston Rod
93964 Piston Rod
61776 Piston Rod
66628 Piston Rod
90595 Piston Rod
90082 Piston Rod
93289 Piston Rod
Figure 12
PN 97999-64
6544X-X (en)
Page 8 of 8
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