Ingersoll Rand Water Pump 6544X X User Manual

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 4-1/4air motors.  
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.  
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.  
Figure 1  
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  
© 2007  
CCN 81582769  
(800) 276-4658 FAX (800) 266-7016  
 
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
NOT SHOWN  
93897-1 Pipe Plug (models 65440 only)  
LUBRICATION / SEALANTS  
3
NOTE: Lubricate with Parker “O” ring lube (ARO p/n  
36460).  
Apply Loctite® 271 to threads.  
8
9
11  
31  
32  
33  
34  
35  
36  
38  
40  
16  
39  
41  
10  
12a  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
24  
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)  
Rod Assembly  
Rod Assembly  
Cylinder  
27  
28  
29  
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  
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)  
43 Snap Ring  
44 Washer  
(1/4” x 1-1/4” o.d.)  
45 U” Cup  
Y186-16  
90103  
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)  
Rod  
Rod  
Rod  
Rod  
Rod  
Rod  
Rod  
Rod  
Rod  
48  
(1/8” x 1” o.d.)  
O” Ring  
O” Ring  
Y325-210  
Y325-220  
Y17-10-C  
61268  
49  
(1/8” x 1-5/8” o.d.)  
(1/8” - 27 N.P.T.)  
52 Pipe Plug  
Items included in Service Kit  
Indicates where parts are used.  
For simplification of ordering and stocking, a Y325-210 “O”  
ring, Y325-220 “Oring and a Y186-16 “Ucup 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.  
“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.  
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  
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).  
27  
42  
29  
52  
28  
49  
21  
44  
46  
47  
43  
45  
18 ꢀ  
30  
48  
Figure 5  
29. Remove (21) “Oring 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) “Oring 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) “Orings from (39) gland.  
25. Remove (29) tube assembly from (30) base.  
26. Remove two (18) “Orings 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) “Ucup and (46) washer.  
Type 2 (see figure 11, page 8): Remove (49) “Oring.  
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) “Orings 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) “Oring 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) “Oring.  
7. Push (48) piston rod thru (30) base assembly, being care-  
ful not to damage the lips of (45) “Ucup or (49) “Oring.  
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) “Orings 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) “Oring 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.  
Worn (35) “O” ring or (34) seal. Replace (35) “O” ring and  
(34) seal.  
Damaged (24) piston assembly. Replace (24) piston as-  
sembly.  
Air leakage around (48) piston rod.  
Worn (45) “Ucup. Replace (45) “Ucup.  
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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