Ingersoll-Rand 6546X-X, 6544X-X manual Reassembly of AIR Motor CONT’D, Trouble Shooting

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.

33.Remove the 90350 special installation tool by pulling up on it.

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.

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.

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.

39.Hold the (11 and 14) inserts against the (31) valve piston

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.

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.

44.Install (10) gasket in (8) air motor cap and secure with six

(3) screws.

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

9 - Valve Guide

12 - Valve Plate and

Pin Assembly

12a - Roll Pin

14 - Valve Insert

13 - Insert Spring

Assembly

4 - Screw (4)

5 - Washer (4)

Figure 10

TROUBLE SHOOTING

Air leakage out of main exhaust. Worn (14) insert. Replace (14) insert.

Worn (12) valve plate and pin assembly. Replace (12) valve plate and pin assembly.

Damaged (24) piston assembly. Replace (24) piston as- sembly.

Continual air leakage out of bleeder hole in (19) head as- sembly.

Worn (35) “O” ring or (34) seal. Replace (35) “O” ring and (34) seal.

Air leakage around (48) piston rod.

Worn (45) “U” cup. Replace (45) “U” cup.

6544X-X (en) Page 7 of 8