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OPERATOR’S MANUAL 6544X-X
INCLUDING: SERVICE KITS, TROUBLESHOOTING, PARTS LIST,
6546X-X
DISASSEMBLY & REASSEMBLY.
RELEASED: 2-26-82
REVISED: 11-28-07
4-1/4” AIR MOTORS
(REV. U)
6544X-X (4” STROKE) and 6546X-X (6” STROKE)
Also covers 61268 service kits
READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
OPERATING OR SERVICING THIS EQUIPMENT.
It is the responsibility of the employer to place this information in the hands of the operator. Keep for future reference.
THIS MANUAL COVERS THE FOLLOWIN
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PARTS LIST / 6544X-X & 6546X-X (size) (size) Item Description (Qty) Part No. Item Description (Qty) Part No. 1 Screw (#8 - 32 x 7/8”) (not shown) (4) Y136-90-S 28 Cylinder (see chart, page 4) (1) - - - - - (not shown) (see chart, page 4) 2 Defl ector (1) 90409 29 Tube (1) - - - - - (#10 - 24 x 1/2”) (see chart, page 4) 3 Screw (6) 95956827 30 Base and Bearing Ass’y (1) - - - - - 4 Screw (#8 - 32 x 3/4”) (4) Y19-89-S 31 Valve Piston (1) 92394 5 Washer (4) 90084 32 Washer (1) 90105
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PARTS LIST / 6544X-X & 6546X-X - (AIR MOTOR HEAD) 50 50 6 6 Part numbers listed below and on parts list (opposite page) are typical. 7 7 NOT SHOWN 93897-1 Pipe Plug (models 65440 only) 4 4 LUBRICATION / SEALANTS 3 3 5 5 NOTE: Lubricate with Parker “O” ring lube (ARO p/n 36460). Apply Loctite® 271 to threads. 8 8 11 11 9 9 31 31 10 10 32 32 12a 12a 12 12 33 33 13 13 34 34 14 14 35 35 15 15 36 36 16 16 38 38 17 17 18 18 40 40 19 19 16 16 20 20 39 39 21 21 41 41 22 22
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PARTS LIST / 6544X-X & 6546X-X AIR MOTOR MODEL NO. (size) Item Description Part No. (Qty) Rod Assembly 90107-1 27 Rod Assembly 90107-2 Cylinder 90090-1 28 Cylinder 90090-2 Tube 79008 29 Tube 90101-1 Tube 90101-2 Tube 94988 Base and Bearing (Stub) 65020 30 Base and Bearing (Stub) 65023 Base and Bearing 65023-2 Base and Bearing 65025 Base and Bearing (Stub) 65775 Base and Bearing (Stub) 65775-2 Base and Bearing (Stub) 90074 Bolt (1/2” - 20 x 10-1/4”) 94046-1 (4) 42 Bolt (1/2” - 20 x
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PARTS LIST / 6544X-X & 6546X-X - (AIR MOTOR PISTON ROD AND BASE) See chart on the opposite page for each model. TORQUE REQUIREMENTS NOTE: DO NOT OVERTIGHTEN FASTENERS. Tighten (48) rod to 50 - 60 ft lbs. (67.8 - 81.3 Nm). LUBRICATION / SEALANTS NOTE: Lubricate with Parker “O” ring lube (ARO p/n 36460). 27 42 29 52 28 49 21 43 44 45 46 18 47 30 48 Figure 5 29. Remove (21) “O” ring from (30) base assembly. DISASSEMBLY OF AIR MOTOR (CONT’D) 30. Separate (48) piston rod and (24) pisto
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15. Push (36) extension rod thru (41) “O” ring in the base of REASSEMBLY OF AIR MOTOR (19) head assembly. 16. Press (19) head assembly down, seating against (28) cyl- 1. Apply grease to all “O” rings, “U” cups and other rubber inder and (29) tube assembly. goods before installing. 17. Insert four (42) bolts down thru the holes in the fl ange of 2. Clean the threads on (27) rod assembly and put the (19) head assembly and (30) base assembly. threaded end thru (24) piston assembly. 18. Screw fo
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and slide the (15) gasket and (12) valve plate between REASSEMBLY OF AIR MOTOR (CONT’D) the two inserts and (19) head assembly. Be sure the 26. Fit the turned diameter of the 90350 special installation larger holes in the (12) valve plate are located in front of tool into the bore in the bottom of (19) head assembly. the larger or (14) insert. Also, be sure the pins are located 27. Place (38) adapter assembly down over (36) extension at the top of the valve plate. rod, with the thread on the
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65440 AND 65462 AIR MOTOR PISTON ROD AND BASE Piston Rod Y325-210 “O” Ring (see item 48, page 4) 93310 Bushing 65020 Base and Bearing Assembly (stub) 93311 Retainer 93312 Guide Y6-66-C Screw (4 req’d) Y14-616-C Lock Washer (4 req’d) 93958 Plate (used on 65440 air motor) 93313 Plate (used on 65462 air motor) Figure 11 ITEM 48 PISTON ROD END VARIETY 65911-2 Piston Rod 90573 Piston Rod 61776 Piston Rod 90082 Piston Rod 90108-1 Piston Rod 93964 Piston Rod 66628 Piston Rod 93289 Piston Rod 90595 Pi
