Ingersoll-Rand 6544X-X, 6546X-X manual Disassembly of AIR Motor

Page 2

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

Item

Description (size)

(Qty)

Part No.

 

 

 

 

1

Screw (#8 - 32 x 7/8”) (not shown)

(4)

Y136-90-S

 

 

 

 

2

Deflector (not shown)

(1)

90409

 

 

 

 

3

Screw (#10 - 24 x 1/2”)

(6)

95956827

 

 

 

 

4

Screw (#8 - 32 x 3/4”)

(4)

Y19-89-S

 

 

 

 

5

Washer

(4)

90084

 

 

 

 

6

Screw (1/4” - 28 x 3/4”)

(2)

Y119-49-C

 

 

 

 

7

Washer (1/4” i.d.)

(2)

Y14-416

 

 

 

 

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 (3/32” o.d. x 3/4” long)

(2)

Y178-26-S

 

 

 

 

13

Insert Spring Assembly

(1)

65032

 

 

 

 

14

Valve Insert

(1)

90796

 

 

 

 

15

Gasket

(1)

90091

 

 

 

 

16

“O” Ring (1/16” x 1-3/8” o.d.)

(2)

Y325-26

 

 

 

 

17

Washer

(1)

91344

 

 

 

 

18

“O” Ring (1/16” x 3/4” o.d.)

(2)

Y325-16

 

 

 

 

19

Head Assembly

(1)

65889

 

 

 

 

20

“U” Cup (3/16” x 1-3/8” o.d.)

(1)

Y186-51

 

 

 

 

21

“O” Ring (1/8” x 4-1/4” o.d.)

(2)

Y325-242

 

 

 

 

22

Screw (#8 - 32 x 3/8”)

(4)

Y136-85-S

 

 

 

 

24

Piston Assembly

(1)

61851

 

 

 

 

27

Rod Assembly (see chart, page 4)

(1)

- - - - -

 

 

 

 

“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).

DISASSEMBLY OF AIR MOTOR

NOTE: All threads are right hand.

1.Place motor in up stroke position. This can be accom- plished by pushing (48) rod toward the top of the air motor.

2.Remove four (1) screws from (2) deflector.

3.Remove (2) deflector.

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

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

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

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

Allen Wrench

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

4 Screws (4)

5 Washers (4)

Figure 2

Item

Description (size)

(Qty)

Part No.

 

 

 

 

28

Cylinder (see chart, page 4)

(1)

- - - - -

 

 

 

 

29

Tube (see chart, page 4)

(1)

- - - - -

 

 

 

 

30

Base and Bearing Ass’y (see chart, page 4)

(1)

- - - - -

 

 

 

 

31

Valve Piston

(1)

92394

 

 

 

 

32

Washer

(1)

90105

 

 

 

 

33

Gland

(1)

91006

 

 

 

 

34

Seal

(1)

91007

 

 

 

 

35

“O” Ring (0.103” x 1.255” o.d.)

(1)

91207

 

 

 

 

36

Extension Rod

(1)

90080

 

 

 

 

38

Adapter

(1)

92393

 

 

 

 

39

Gland

(1)

90114

 

 

 

 

40

Washer

(1)

91345

 

 

 

 

41

“O” Ring (1/16” x 7/16” o.d.)

(1)

Y325-11

 

 

 

 

42

Bolt (see chart, page 4)

(4)

- - - - -

 

 

 

 

43

Snap Ring (see chart, page 4)

(1)

- - - - -

 

 

 

 

44

Washer (see chart, page 4)

(1)

- - - - -

 

 

 

 

45

“U” Cup (see chart, page 4)

(1)

- - - - -

 

 

 

 

46

Washer (see chart, page 4)

(1)

- - - - -

 

 

 

 

47

Nut (see chart, page 4)

(4)

- - - - -

 

 

 

 

48

Piston Rod (see chart, page 4)

(1)

- - - - -

 

 

 

 

49

“O” Ring (see chart, page 4)

(1)

- - - - -

 

 

 

 

50

Ground Lug

(1)

93006

 

 

 

 

51

Ground Label (not shown)

(1)

93007

 

 

 

 

 

Items included in Service Kit

 

61268

 

 

 

 

7.Remove four (4) screws and four (5) washers from (19) head assembly by pressing outward with a small allen wrench, as illustrated in figure 2.

8.With the aid of a screwdriver, unhook the legs of (13) in- sert spring assembly from the bottom of (12) valve plate.

9.Remove (12) valve plate and (13) insert spring assembly 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.

10.Remove both (11 and 14) inserts and (13) insert spring assembly from (12) valve plate.

11.Remove (15) gasket from (19) head assembly.

12.Remove two (6) screws and two (7) lock washers from (33) gland in (19) head assembly.

13.With fingers, pull (31) valve piston upward until (33) gland has pulled out of its chamber.

14.Remove (33) gland by sliding it up over (31) valve piston.

15.Remove (34) seal and (35) “O” ring from (33) gland (see figure 8, page 6).

16.Disassemble (31) valve piston from (38) adapter as shown in figure 4, page 3.

17.Pull (38) adapter upward until assembly is taut and grasp (36) extension rod with fingers, as shown in figure 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 re- move (38) adapter.

18.Remove (17) washer and (20) “U” cup from (38) adapter.

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

20.Remove four (42) bolts.

21.Remove (19) head assembly and place on the work- bench with (8) cap side down. This action will allow (40) washer to fall out of its cavity.

(continued on page 5)

Page 2 of 8

6544X-X (en)

Image 2
Contents General Description Service KitsMaintenance Disassembly of AIR Motor Apply Loctite 271 to threads Parts List / 6544X-X & 6546X-X AIR Motor HeadPipe Plug models 65440 only Y147-131 Washer 73986 94046-194046-2 Y186-16 Washer 90103Disassembly of AIR Motor CONT’D Tighten 48 rod to 50 60 ft lbs .8 81.3 NmReassembly of AIR Motor Push 24 piston assembly to the top of 28 cylinderReassembly of AIR Motor CONT’D Trouble Shooting65462 AIR Motor Piston ROD and Base Item 48 Piston ROD END Variety

6546X-X, 6544X-X specifications

The Ingersoll-Rand 6544X-X and 6546X-X air compressors are part of a well-regarded line that caters to industries requiring a reliable source of compressed air. These models are designed to deliver robust performance and efficiency, aligning with modern industrial demands. Both models exhibit a variety of features that make them stand out in the market.

One of the most notable features of the Ingersoll-Rand 6544X-X and 6546X-X is their durability. Engineered with high-quality materials, these compressors are designed to withstand the rigors of constant use in challenging environments. The reinforced construction ensures longevity and reliability, minimizing downtime and maintenance costs.

The 6544X-X and 6546X-X models utilize advanced rotary screw technology. This technology is known for its energy efficiency compared to traditional reciprocating compressors, providing significant savings in operational costs. The rotary screw design allows for continuous airflow, making it ideal for applications requiring a constant supply of compressed air.

Furthermore, these compressors are equipped with an innovative cooling system that maintains optimal operating temperatures. This not only enhances performance but also extends the lifespan of the unit. The cooling system is designed to be efficient, reducing energy consumption while ensuring that the compressor operates within recommended temperature ranges.

In terms of user interface, both models feature an intuitive control panel that simplifies operation. Users can easily adjust settings, monitor performance metrics, and quickly troubleshoot any issues. This user-friendly design enhances operational efficiency and reduces the learning curve for new operators.

The Ingersoll-Rand 6544X-X and 6546X-X also emphasize noise reduction. Designed with sound-dampening features, these compressors operate quietly, making them suitable for environments where noise levels must be kept to a minimum. This feature is particularly beneficial in settings like workshops or manufacturing plants where a quieter operation is needed.

In summary, the Ingersoll-Rand 6544X-X and 6546X-X compressors provide a potent combination of durability, efficiency, and advanced technology. Their rotary screw design, enhanced cooling systems, user-friendly interfaces, and noise reduction technologies collectively position them as excellent solutions for various industrial applications, ensuring reliable compressed air delivery for maximum productivity.