Reassembly of AIR Motor

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).

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.

28 Cylinder (apply grease throughout inside)

Apply grease

48 Piston Rod

Figure 6

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.

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) 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).

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.

	16	- “O” Ring
	35	- “O” Ring
	34	- Seal
	Direction for sizing
	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 fingers (see figure 9 below).

32 Washer	36 Extension Rod
32 Washer
groove

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 6 of 8

6544X-X (en)

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.