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

 

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)

Page 6
Image 6
Ingersoll-Rand 6544X-X, 6546X-X manual Reassembly of AIR Motor, Push 24 piston assembly to the top of 28 cylinder

6546X-X, 6544X-X specifications

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