OPERATOR’S MANUAL
6564X-X
6566X-X
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE
66620
6” AIR MOTORS
6564X-X and 66620
RELEASED: 8-28-91
REVISED:
(REV. K)
10-11-01
6566X-X
6” STROKE
4” STROKE
READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.
THIS MANUAL COVERS THE FOLLOWING MODELS
MODEL
65643
65645
65662
65665Ć2B
65666
66620
65665ĆB
SERVICE KITS
61355 for general repair of all 6" air motors.
GENERAL DESCRIPTION
The 6" air motor is a general purpose power unit and is used with many
2Ćball, 4Ćball 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 exĆ
haust port to reduce noise to acceptable 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 capaĆ
ble 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 nonĆ
detergent gear oil, set at a rate not to exceed 1 or 2 drops per minute.
NOTICE
DO NOT OPERATE AIR MOTOR ABOVE RECOMMENDED
AIR PRESSURE OF 150 P.S.I. (10.3 BAR) OR 75 CYCLES PER
MINUTE. Air motor may be rated differently in the next assembly.
Check model plate.
INGERSOLL-RAND COMPANY
P.O. BOX 151 D ONE ARO CENTER D BRYAN, OHIO 43506Ć0151
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AIR MOTOR HEAD
PART NUMBERS LISTED BELOW AND ON PARTS
LIST (OPPOSITE PAGE) ARE TYPICAL.
6
7
1
41
4
3
5
2
9
8
31
32
10
11
12
13
14
33
34
Q 35
36
15
16
18
17
19
20
21
23
22
24
25
Q
37
39
38
42
Q
Q
40
44
43
Q
4
5
FIGURE 2
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‘‘O” RING LUBE (ARO P/N 36460).
31
42
6564XĆX
PAGE 3 OF 8
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Q
AIR MOTOR MODEL NO.
AIR MOTOR PARTS LIST
D
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MODELS NO LONGER ACTIVE, SHOWN
FOR REFERENCE ONLY.
ITEM
DESCRIPTION
PART # (QTY)
26
27
28
j
Valve Rod
90107Ć1
90107Ć2
90215Ć1
90215Ć2
90485Ć1
90485Ć2
Y325Ć210
65065
Valve Rod
j
Air Cylinder
Air Cylinder
Tube
Tube
29
30
n
O" Ring
Air Motor Base Assembly
Air Motor Base Assembly
Air Motor Base Assembly
Air Motor Base Assembly
Bolt (1/2" Ć 20 x 10Ć1/4")
Bolt (1/2" Ć 20 x 8Ć1/4")
Retaining Ring
Guide Washer
U" Cup
65065Ć2
65067
L
65868
46
94046Ć1 (4)
94046Ć2 (4)
Y147Ć131
73986
47
48
49
50
51
52
j
j
n
Y186Ć16
Y11Ć8ĆC (4)
90103
Nut
j
j
Washer
Piston Rod
66628
Piston Rod
90082
Piston Rod
90108Ć1
90108Ć2
Piston Rod
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= INDICATES WHERE
PARTS ARE USED.
n PARTS SO MARKED ARE ALSO INĆ
CLUDED IN 61355 SERVICE KIT.
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NOTE: Base styles and lower packings may vary from that shown on
the cover. Refer to model number in the chart above.
L On model 65662 air motors, a plate is mounted on the bottom of the
(30) base. Therefore, the following parts are different and illustrated on
page 8.
For simplification of ordering and stocking, a Y325Ć210 O" ring and a
Y186Ć16 U" cup will be included in 61355 service kit. When repairing
the motor, use only the one that is needed.
93310 Bushing
93311 Retainer
93312 Guide
All of the service parts are the same for all motors except the lower pisĆ
ton rod packing.
93313 Plate (note the orientation of the plate with the air inlet)
Y6Ć66ĆC Screw (4 req'd)
Y14Ć616ĆC Lock Washer (4 req'd)
NOTE: It is highly recommended that a 90350 installation tool be used.
This will greatly ease installation of (42) piston adapter and piston
valve and will reduce the chances of damage to the (19) U" cup. A
damaged (19) U" cup can usually lead to air motor failure.
90350 INSTALLATION TOOL
PAGE 4 OF 8
6564XĆX
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AIR MOTOR PISTON ROD AND BASE
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B
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SEE CHART ON OPPOSITE PAGE FOR EACH MODEL.
‘‘O” RING LUBE (ARO P/N 36460).
46
26
27
28
Q
2
0
29
17
Q
Q
47
Q
4
9
48
50
51
52
30
FIGURE 4
DISASSEMBLY OF AIR MOTOR (CONTINUED)
16. Remove the (37) upper gland.
17. Remove the (38) seal and (39 and 15) O" rings from the (37) upper
gland (see figure 7).
29. Remove the (28) tube.
30. Remove the (17) O" ring from the (30) air motor base assembly and
(18) head assembly.
18. Disassemble the (31) valve piston from the (42) piston adapter (see
figure 3).
19. Remove the (31) valve piston.
20. Pull the (42) piston adapter upward and grasp the (40) extension rod
below the (42) piston adapter. Push the (42) piston adapter down on
the (40) extension rod. Remove the (36) washer and (42) piston
adapter.
31. Pull upward on the (27) air cylinder until the (52) piston rod is sepaĆ
rated from the (30) air motor base assembly. If the (52) piston rod
does not separate from the (30) air motor base assembly, remove
the (52) piston rod after removal of the (27) air cylinder.
32. Remove the (20) O" ring from the (30) air motor base assembly.
33. Remove the (47) retaining ring, (48) guide washer, (49) U" cup and
(51) washer from the (30) air motor base assembly.
21. Remove the (16) washer and the (19) U" cup from the (42) piston
adapter.
22. Remove the four (50) nuts from the four (46) bolts.
23. Remove the four (46) bolts.
24. Remove the (18) head assembly and place it on the workbench with
the end that the (28) tube fits in upward".
25. Remove the (20) O" ring from the (18) head assembly.
26. Remove the four (21) machine screws from the (43) lower gland.
27. Remove the (43) lower gland.
34. Unscrew the (40) extension rod from the (26) valve rod by holding
the (26) valve rod with adjustable type pliers and placing a wrench
on the provided wrench flat at the top of (40) extension rod.
35. Unscrew the (52) piston rod from (22) adapter, using wrench flats on
(52) piston rod. Remove (26) valve rod from (52) piston rod.
NOTE: Caution should be exercised so as not to mar or damage the finĆ
ish on (40) extension rod or (52) piston rod.
36. Remove (25) nut, (23) piston assembly and (24) O" ring from (22)
adapter.
28. Remove the (44) washer and (15 and 45) O" rings from the (43) lowĆ
er gland.
6564XĆX
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13. Fill the area between the lips of (23) piston assembly with grease,
then insert into the bottom of the (27) air cylinder (see figure 3).
14. Push the (23) piston assembly to the top of the (27) air cylinder.
15. Thoroughly grease and install the (45 and 20) O" rings into the (18)
head assembly.
16. Thoroughly grease the two (17) O" rings and install one in the (30)
air motor base assembly. Install the other in the (18) head assembly.
17. Press the (28) tube into the counterbored hole in the (30) air motor
base assembly.
18. Push the (40) extension rod thru the (45) O" ring in the base of the
(18) head assembly.
19. Press the (18) head assembly down until the (27) air cylinder and
(28) tube are seated in the (18) head assembly.
20. Insert the four (46) bolts down thru the holes in the flanges of the (18)
head assembly and the (30) air motor base assembly.
21. Screw the four (50) nuts on the four (46) bolts. Alternately and evenly
tighten the nuts.
22. Thoroughly grease and install the (19) U" cup in the (42) piston
adapter, with the lips of the (19) U" cup down toward the thick flange
on the (42) piston adapter.
23. Thoroughly grease and install the (39 and 15) O" rings in the (37)
upper gland.
24. Bend the (38) seal in a heart shape and install in the (37) upper gland
inside the (39) O" ring (see figure 6).
REASSEMBLY OF AIR MOTOR
NOTE: ALL THREADS ARE RIGHT HAND.
Apply grease to all O" rings, U" cups and other rubber goods when
installing.
1. Slip the (24) O" ring on the (22) adapter, clean with solvent and apĆ
ply Loctite 271 to the external threads of the (22) adapter. Assemble
the (22) adapter and (25) nut to the (23) piston assembly and tighten
to 160 Ć 180 ft lbs.
2. Put the threaded end of the (26) valve rod thru the hole in the (22)
adapter, with the machined shoulder" end of the (26) valve rod on
the threaded side of the (22) adapter.
3. While holding the (26) valve rod below the threads with locking pliĆ
ers, clean with solvent and apply Loctite 271 to the threads and atĆ
tach the (40) extension rod, using the provided wrench flats.
4. Place the machined shoulder" end of the (26) valve rod into the hole
in the end of the (52) piston rod and assemble (52) piston rod to (22)
adapter, tightening using a wrench on flats provided.
5. Thoroughly grease and install the (20) O" ring in the (30) air motor
base assembly.
6. Grease and place the (51) washer and (49) U" cup into the (30) air
motor base assembly. Place the (48) guide washer and (47) retainĆ
ing ring in the (30) air motor base assembly.
7. Grease and install (15) O" ring on the (43) lower gland.
8. Grease the bore in the (18) head assembly and insert the (43) lower
gland into the bore of the (18) head assembly, using a twisting moĆ
tion.
9. Align the screw holes in the (43) lower gland and (18) head assembly.
10. Secure the (43) lower gland to the (18) head assembly using four
(21) machine screws.
11. Put the (52) piston rod thru the (49) U" cup in the (30) air motor base
assembly, being careful not to damage the U" cup.
12. Thoroughly grease the inside of the (27) air cylinder.
SEAL FREE FORM
SEAL COLLAPSED FORM
PUSH SIDES IN, AS SHOWN, THEN SLIDE INTO BORE AND POSIĆ
TION SEAL IN GROOVE.
27 CYLINDER (APPLY
GREASE THROUGHOUT
INSIDE)
FIGURE 6
25. Grease and carefully push the (31) valve piston into the (37) upper
gland to size the (38) seal, then remove (see figure 7 below).
15 ``O" RING
39 ``O" RING
23 PISTON
(APPLY GREASE
AROUND EDGE)
38 SEAL
DIRECTION FOR SIZING
31 VALVE PISTON
37 UPPER GLAND
52 PISTON ROD
FIGURE 7
26. Place the (44) washer over the (40) extension rod.
27. Pull the (40) extension rod up and grasp with two fingers (see figure 8).
28. Place the 90350 installation tool over the (40) extension rod, with the
turned diameter down and the chamfer up.
29. Fit the turned diameter of the 90350 installation tool into the bore in
the bottom of the (18) head assembly.
30. Place the (42) piston adapter down over the (40) extension rod, with
the threads up.
31. Insert the (36) washer into the groove in the top of the (40) extension
rod.
FIGURE 5
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6564XĆX
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42. Thoroughly grease and insert the (14) gasket and the (11) valve
plate and pin assembly between the (13) valve insert and the (18)
head assembly, with the two pins in the (11) valve plate and pin asĆ
sembly up (see figures 2 and 9).
43. Hook the round coils in the (12) insert spring assembly over the pins
in the (11) valve plate and pin assembly (see figure 9).
44. Hook the bottoms of the (12) insert spring assembly into the holes on
the side of the (11) valve plate and pin assembly.
36 WASHER GROOVE
40 EXTENSION ROD
45. Insert the (9) valve guide against the face of the (11) valve plate and
pin assembly. The legs of the (9) valve guide should be down, with
the leg having the threaded hole the farthest from the bottom toward
the air inlet in the (18) head assembly.
46. Insert and tighten across corners of eight (4) machine screws and
eight (5) washers (see figures 1 and 9).
47. Thoroughly grease and install the (10) gasket in the (8) air motor
cap.
48. Place the (8) air motor cap on the (18) head assembly and secure
with the six (3) screws (see figure 2).
49. Place the (2) deflector on exhaust port of the (18) head assembly,
with the opening down, and secure with four (1) machine screws
(see figure 2).
FIGURE 8
32. Pull the (42) piston adapter up around the (36) washer.
33. Place the (16) washer over the (40) extension rod and into the (42)
piston adapter.
34. Clean with solvent and put Loctite 271 on the threads of the (31)
valve piston. Screw the (31) valve piston into the (42) piston adapter
and tighten (see figure 3).
35. Push the assembled (42) piston adapter and (31) valve piston down
thru the 90350 installation tool until they bottom.
36. Remove the 90350 installation tool.
37. Install the (37) upper gland over the (31) valve piston and push
down, being careful to retain the (38) seal in the O" ring groove.
38. Align the two bolt holes and secure the (37) upper gland to the (18)
head assembly with the two (6) machine screws and two (7) lock
washers (see figure 9).
39. Insert the (12) insert spring assembly in the (18) head assembly,
with the hooks down and the nylon roller toward the (31) valve piston
(see figures 2 and 9).
40. Thoroughly grease and insert the (34) pilot insert, two (35) valve
guides, (33) valve plate and (32) gasket into the (18) head assembly
(see figure 9).
4 SCREW (8)
5 WASHER (8)
32 GASKET
33 VALVE PLATE
35 VALVE GUIDE (2)
37 UPPER GLAND
6 SCREW (2)
7 LOCK WASHER (2)
12 SPRING ASS'Y
9 VALVE GUIDE
11 VALVE PLATE
14 GASKET
18 HEAD ASSEMBLY
FIGURE 9
41. Thoroughly grease and insert the (13) valve insert into the (18) head
assembly (see figure 2).
TROUBLE SHOOTING
PROBLEM
Air leakage out of main exhaust.
CAUSE
PROBLEM
Continual air leakage out of bleeder hole in (18) head assembly.
CAUSE
Worn (13) valve insert.
REMEDY
Replace (13) valve insert.
CAUSE
Worn (15) O" ring or (38) seal.
REMEDY
Replace (15) O" ring and (38) seal.
Worn (11) valve plate and pin assembly.
REMEDY
Replace (11) valve plate and pin assembly.
CAUSE
PROBLEM
Air leakage around (52) piston rod.
CAUSE
Worn (49) U" cup.
Damaged (23) piston assembly.
REMEDY
Replace (23) piston assembly.
REMEDY
Replace (49) U" cup.
6564XĆX
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65662 AIR MOTOR PISTON ROD & BASE
Y325-210 “O” Ring
90108-1 Piston Rod
93310 Bushing
93311 Retainer
65868 Air Motor Base
Ass’y. (Stub)
93312 Guide
93313 Plate
Y6-66-C
Screw (4 req’d)
Y14-616-C
Lock Washer (4 req’d)
ITEM 52 PISTON ROD END VARIETY
90108-1 Piston Rod
90108-2 Piston Rod
66628 Piston Rod
90082 Piston Rod
P/N 97999Ć174
6564XĆX
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