Ingersoll Rand 66615X X C Users Manual 66615X_X_C_Y_

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66615X-X-C

OPERATOR’S MANUAL
INCLUDING: OPERATION, INSTALLATION & MAINTENANCE

RELEASED:
REVISED:
(REV. AB)

1-1/2” DIAPHRAGM PUMP

5-31-88
12-1-10

1:1 RATIO (METALLIC)
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.

SERVICE KITS
Refer to the Model Description Chart to match the pump material options.
637118-C for air section repair (see page 6).
637124-XX for fluid section repair (see page 4).
637155 Abrasion Resistant Conversion Kit is available for use in heavy
and abrasive material applications (see page 4).

PUMP DATA
Models . . . . . . . . . . . . see “Model Description Chart” for “-XXX”
Pump Type . . . . . . . . . Metallic Air Operated Double Diaphragm
Material . . . . . . . . . . . . see “Model Description Chart”
Weight . . . . Aluminum . . . . . . . . . . . 51.54 lbs (23.4 kgs)
Cast Iron . . . . . . . . . . . . 79.54 lbs (36.1 kgs)
Stainless Steel . . . . . . . . 84.54 lbs (38.3 kgs)
[add 23 lbs (10.4 kgs) for cast iron air motor section]
Maximum Air Inlet Pressure . . . . . . . . 120 p.s.i. (8.3 bar)
Maximum Material Inlet Pressure . . . . 10 p.s.i. (0.69 bar)
Maximum Outlet Pressure . . . . . . . . . 120 p.s.i. (8.3 bar)
Maximum Flow Rate (flooded inlet) . . . . 90 g.p.m. (340.7 l.p.m.)
Displacement / Cycle @ 100 p.s.i.g. . . 0.64 gal. (2.42 lit.)
Maximum Particle Size . . . . . . . . . . . 1/4” dia. (6.4 mm)
Maximum Temperature Limits (diaphragm / ball / seat material)
Acetal . . . . . . . . . . . . . . . . . 10_ to 180_ F (-12_ to 82_ C)
E.P.R. . . . . . . . . . . . . . . . . . -60_ to 280_ F (-51_ to 138_ C)
HytrelR . . . . . . . . . . . . . . . -20_ to 150_ F (-29_ to 66_ C)
KynarR PVDF . . . . . . . . . . . 10_ to 200_ F (-12_ to 93_ C)
Neoprene . . . . . . . . . . . . . . 0_ to 200_ F (-18_ to 93_ C)
Nitrile . . . . . . . . . . . . . . . . . 10_ to 180_ F (-12_ to 82_ C)
Polypropylene
. . . . . . . . . 35_
. . to 175_ F (2_ to 79_ C)
Polyurethane . . . . . . . . . . . . 10_ to 150_ F (-12_ to 66_ C)
PTFE . . . . . . . . . . . . . . . . . 40_ to 225_ F (4_ to 107_ C)
SantopreneR . . . . . . . . . . . -40_ to 225_ F (-40_ to 107_ C)
VitonR . . . . . . . . . . . . . . . . -40_ to 350_ F (-40_ to 177_ C)
Dimensional Data . . . . . . . . . . . . . . . see page 8
Noise Level @ 70 p.s.i. - 60 c.p.m. . . 77.7 dba(A)
 Tested with 93139 muffler assembly installed.
 The pump sound pressure levels published here have been updated to an Equivalent
Continuous Sound Level (LAeq) to meet the intent of ANSI S1.13-1971, CAGI-PNEUROP S5.1 using four microphone locations.

NOTICE: All possible options are shown in the chart. However, certain
combinations may not be recommended, consult a representative or the
factory if you have questions concerning availability.

66615X-XXX-C
1-1/2” DIAPHRAGM PUMP

Figure 1

MODEL DESCRIPTION CHART
6661 X X - X X X - C
Center Body Material, Threads
5 - Aluminum, N.P.T.F.
7 - Aluminum, BSP
6 - Cast Iron, N.P.T.F.
8 - Cast Iron, BSP
Fluid Cap / Manifold Material, Hardware
(Steel Hardware)

(Stainless Steel Hardware)

0 - Aluminum
1 - Stainless Steel
2 - Cast Iron

A - Aluminum
B - Stainless Steel
C - Cast Iron

Seat Material
1 - Aluminum
2 - 316 Stainless Steel
3 - Polypropylene

4 - Kynar PVDF
5 - Carbon Steel
8 - 440 Stainless Steel

Ball Material
1 - Neoprene
2 - Nitrile
3 - Viton
4 - PTFE
5 - E.P.R.

6
8
A
C
E

Diaphragm Material
1 - Neoprene
2 - Nitrile
3 - Viton
4 - PTFE / Santoprene

- Acetal
- Polyurethane
- Stainless Steel
- Hytrel
- Santoprene

5 - E.P.R.
9 - Hytrel
B - Santoprene

FLUID SECTION SERVICE KIT SELECTION
EXAMPLE: MODEL # 666150-361-C
FLUID SECTION SERVICE KIT # 637124-61

INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET -- BRYAN, OHIO 43506

	 (800) 276-4658 D FAX (800) 266-7016
www.ingersollrandproducts.com

E2010

CCN 81660219

6661XX - X X X - C
637124 - X X
Ball

Diaphragm

OPERATING AND SAFETY PRECAUTIONS

S
S

S
S

S
S
S
S
S
S
S
S
S

S
S
S

S

READ, UNDERSTAND AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.
WARNING HAZARDOUS MATERIALS. Can cause serious inHAZARDOUS MATERIALS
EXCESSIVE AIR PRESSURE
jury or property damage. Do not attempt to return a pump to the
HAZARDOUS PRESSURE
STATIC SPARK
factory or service center that contains hazardous material.
Safe handling practices must comply with local and national
laws and safety code requirements.
WARNING EXCESSIVE AIR PRESSURE. Can cause personS Obtain Material Safety Data Sheets on all materials from the
al injury, pump damage or property damage.
supplier for proper handling instructions.
Do not exceed the maximum inlet air pressure as stated on the
WARNING EXPLOSION HAZARD. Models containing alumipump model plate.
Be sure material hoses and other components are able to withnum wetted parts cannot be used with 1,1,1-trichloroethane,
stand fluid pressures developed by this pump. Check all hoses
methylene chloride or other halogenated hydrocarbon solfor damage or wear. Be certain dispensing device is clean and
vents which may react and explode.
in proper working condition.
S Check pump motor section, fluid caps, manifolds and all
wetted parts to assure compatibility before using with solvents
WARNING STATIC SPARK. Can cause explosion resulting in
of this type.
severe injury or death. Ground pump and pumping system.
CAUTION Verify the chemical compatibility of the pump
Sparks can ignite flammable material and vapors.
The pumping system and object being sprayed must be
wetted parts and the substance being pumped, flushed or regrounded when it is pumping, flushing, recirculating or spraycirculated. Chemical compatibility may change with temperaing flammable materials such as paints, solvents, lacquers,
ture and concentration of the chemical(s) within the
etc. or used in a location where surrounding atmosphere is
substances being pumped, flushed or circulated. For specific
conducive to spontaneous combustion. Ground the dispensfluid compatibility, consult the chemical manufacturer.
ing valve or device, containers, hoses and any object to which
CAUTION Maximum temperatures are based on mechanimaterial is being pumped.
cal stress only. Certain chemicals will significantly reduce
Use the pump grounding screw terminal provided. Use AROR
maximum safe operating temperature. Consult the chemical
part no. 66885-1 ground kit or connect a suitable ground wire
manufacturer for chemical compatibility and temperature lim(12 ga. minimum) to a good earth ground source.
its. Refer to PUMP DATA on page 1 of this manual.
Secure pump, connections and all contact points to avoid
CAUTION Be certain all operators of this equipment have
vibration and generation of contact or static spark.
been trained for safe working practices, understand it’s limitaConsult local building codes and electrical codes for specific
tions and wear safety goggles / equipment when required.
grounding requirements.
CAUTION
Do not use the pump for the structural support of
After grounding, periodically verify continuity of electrical path
the
piping
system.
Be certain the system components are
to ground. Test with an ohmmeter from each component (e.g.,
properly supported to prevent stress on the pump parts.
hoses, pump, clamps, container, spray gun, etc.) to ground to
S Suction and discharge connections should be flexible connecinsure continuity. Ohmmeter should show 0.1 ohms or less.
tions (such as hose), not rigid piped, and should be compatible
Submerse the outlet hose end, dispensing valve or device in
with the substance being pumped.
the material being dispensed if possible. (Avoid free streaming
CAUTION Prevent unnecessary damage to the pump. Do
of material being dispensed.)
Use hoses incorporating a static wire.
not allow pump to operate when out of material for long periods
Use proper ventilation.
of time.
Keep inflammables away from heat, open flames and sparks.
S Disconnect air line from pump when system sits idle for long
Keep containers closed when not in use.
periods of time.
WARNING Pump exhaust may contain contaminants. Can
CAUTION Use only genuine ARO replacement parts to ascause severe injury. Pipe exhaust away from work area and persure compatible pressure rating and longest service life.
sonnel.
NOTICE
Replacement warning labels are available upon
In the event of a diaphragm rupture, material can be forced out
request: “Static Spark” (93616-1) & “Diaphragm Rupture”
of the air exhaust muffler.
(93122).
Pipe the exhaust to a safe remote location when pumping hazardous or inflammable materials.
Use a grounded 3/4” minimum i.d. hose between the pump and
WARNING = Hazards or unsafe practices which could
the muffler.
result in severe personal injury, death or
WARNING HAZARDOUS PRESSURE. Can result in serious
substantial property damage.
injury or property damage. Do not service or clean pump,
=
CAUTION Hazards or unsafe practices which could
hoses or dispensing valve while the system is pressurized.
result in minor personal injury, product or
Disconnect air supply line and relieve pressure from the sysproperty damage.
tem by opening dispensing valve or device and / or carefully
=
Important
installation, operation or
NOTICE
and slowly loosening and removing outlet hose or piping from
maintenance information.
pump.

Page 2 of 8

66615X-X-C (en)

GENERAL DESCRIPTION

MAINTENANCE

The ARO diaphragm pump offers high volume delivery even at low air
pressure and a broad range of material compatibility options available.
Refer to the model and option chart. ARO pumps feature stall resistant
design, modular air motor / fluid sections.
Air operated double diaphragm pumps utilize a pressure differential in
the air chambers to alternately create suction and positive fluid pressure
in the fluid chambers, valve checks insure a positive flow of fluid.
Pump cycling will begin as air pressure is applied and it will continue to
pump and keep up with the demand. It will build and maintain line pressure and will stop cycling once maximum line pressure is reached (dispensing device closed) and will resume pumping as needed.

Refer to the part views and descriptions as provided on pages 4 through
7 for parts identification and service kit information.
S Certain ARO “Smart Parts” are indicated which should be available
for fast repair and reduction of down time.
S Service kits are divided to service two separate diaphragm pump
functions: 1. AIR SECTION, 2. FLUID SECTION. The FLUID SECTION is divided further to match typical part MATERIAL OPTIONS.
S Provide a clean work surface to protect sensitive internal moving
parts from contamination from dirt and foreign matter during service
disassembly and reassembly.
S Keep good records of service activity and include pump in preventive maintenance program.
S Before disassembling, empty captured material in the outlet manifold by turning the pump upside down to drain material from the
pump.

AIR AND LUBE REQUIREMENTS
WARNING EXCESSIVE AIR PRESSURE. Can cause pump
damage, personal injury or property damage.
S A filter capable of filtering out particles larger than 50 microns should
be used on the air supply. There is no lubrication required other than
the “O” ring lubricant which is applied during assembly or repair.
S If lubricated air is present, make sure that it is compatible with the “O”
rings and seals in the air motor section of the pump.

OPERATING INSTRUCTIONS
S Always flush the pump with a solvent compatible with the material
S
S
S
S

being pumped if the material being pumped is subject to “setting up”
when not in use for a period of time.
Disconnect the air supply from the pump if it is to be inactive for a few
hours.
The outlet material volume is governed not only by the air supply, but
also by the material supply available at the inlet. The material supply
tubing should not be too small or restrictive. Be sure not to use hose
which might collapse.
When the diaphragm pump is used in a forced-feed (flooded inlet)
situation, it is recommended that a “Check Valve” be installed at the
air inlet.
Secure the diaphragm pump legs to a suitable surface to insure
against damage by vibration.

FLUID SECTION DISASSEMBLY
1. Remove top manifold(s).
2. Remove (22) balls, (19) “O” rings and (21) seats.
3. Remove (15) fluid caps.
NOTE: Only PTFE diaphragm models use a primary diaphragm (7) and
a backup diaphragm (8). Refer to the auxiliary view in the Fluid Section
illustration.
4. Remove the (14) screws, (6) washers, (7) or (7 / 8) diaphragms and
(5) washers.
5. Remove (3) “O” rings.
NOTE: Do not scratch or mar the surface of (1) diaphragm rod.

FLUID SECTION REASSEMBLY
S Reassemble in reverse order.
S Clean and inspect all parts. Replace worn or damaged parts with
new parts as required.

S Lubricate (1) diaphragm rod and (2) “O” ring with Key-Lube “O” ring
lube.

S Use ARO pn / 98931-T bullet (installation tool) to aid in installation of
(2) “O” ring on (1) diaphragm rod.

S Be certain (7) or (7 / 8) diaphragm(s) align properly with (15) fluid

caps before making final torque adjustments on bolt and nuts to
avoid twisting the diaphragm.
S For models with PTFE diaphragms: Item (8) Santoprene diaphragm
is installed with the side marked “AIR SIDE” towards the pump center body. Install the PTFE diaphragm with the side marked “FLUID
SIDE” towards the fluid cap.
S Re-check torque settings after pump has been re-started and run a
while.

S VitonR and HytrelR are trademarks of the DuPont Company S KynarR is a trademark of Arkema Inc. S LoctiteR is a registered trademark of Henkel Loctite Corporation S
S SantopreneR is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. S AROR is a registered trademark of Ingersoll-Rand Company S

66615X-X-C (en)

Page 3 of 8

PARTS LIST / 66615X-X-C FLUID SECTION
L 637124-XX Fluid Section Service Kits include: BALLS (see Ball Option, refer to -XX in chart below), DIAPHRAGMS (see Diaphragm Option, refer to -XX
in chart below), 93706-1 Key-Lube grease packet, plus items: 2, 3, 9 and 19.

SEAT OPTIONS
“21”

MATERIAL CODE

BALL OPTIONS
L “22” (1-3/4” dia.)

-XXX

Seat

Qty

[Mtl]

-XXX

Ball

Qty

[Mtl]

-XXX

Ball

Qty

[Mtl]

-1XX
-2XX

92760
92776

(4)
(4)

[A]
[SS]

-X1X
-X2X

92757-1
92757-2

(4)
(4)

[N]
[B]

-X8X
-XAX

92757-8
94804

(4)
(4)

[U]
[SS]

-3XX

92924

(4)

[P]

-X3X

92757-3

(4)

[V]

-XCX

92757-C

(4)

[H]

-4XX

94514

(4)

[K]

-X4X

92757-4

(4)

[T]

-XEX

92757-A

(4)

[Sp]

-5XX

95676

(4)

[C]

-X5X

92757-5

(4)

[E]

-8XX

93266

(4)

[SH]

-X6X

92757-6

(4)

[D]

L Service Kit

L

DIAPHRAGM OPTIONS
L “8”

“7”

L

“3” (1/16” x 3/4” o.d.)

[A] = Aluminum
[B] = Nitrile
[C] = Carbon Steel
[CI] = Cast Iron
[Co] = Copper
[D] = Acetal
[E] = E.P.R.
[H] = Hytrel
[K] = Kynar PVDF
[N] = Neoprene
[P] = Polypropylene
[SH] = Hard Stainless Steel
[Sp] = Santoprene
[SS] = Stainless Steel
[T] = PTFE
[U] = Polyurethane
[V] = Viton

L

“19” (1/8” x 2-3/4” o.d.)

-XXX

-XX = (Ball)
-XX = (Diaphragm) Diaphragm

Qty

[Mtl]

Diaphragm

Qty

[Mtl]

“O” Ring

Qty

[Mtl]

“O” Ring

Qty

[Mtl]

-XX1
-XX2

637124-X1
637124-X2

92755-1
94615-G

(2)
(2)

[N]
[B]

---------

-----

-----

Y325-16
Y325-16

(4)
(4)

[B]
[B]

Y325-230
Y325-230

(4)
(4)

[B]
[B]

-XX3

637124-X3

92755-3

(2)

[V]

-----

---

---

Y328-16

(4)

[T]

Y327-230

(4)

[V]

-XX4

637124-X4

94617

(2)

[T]

94616

(2)

[Sp]

Y328-16

(4)

[T]

Y220-230

(4)

[T]

-XX5

637124-X5

92755-5

(2)

[E]

-----

---

---

Y328-16

(4)

[T]

92761

(4)

[E]

-XX9

637124-X9

94615-9

(2)

[H]

-----

---

---

Y328-16

(4)

[T]

Y327-230

(4)

[V]

-XXB

637124-XB

94615-A

(2)

[Sp]

-----

---

---

Y328-16

(4)

[T]

92761

(4)

[E]

WETTED PARTS OPTIONS
Aluminum

Stainless Steel

6661X0-X, 6661XA-X
Item

Description (size)

N.P.T.F.

BSP

Cast Iron

6661X1-X, 6661XB-X
N.P.T.F.

BSP

6661X2-X, 6661XC-X
N.P.T.F.

BSP

Qty

Part No.

Part No.

[Mtl]

Part No.

Part No.

[Mtl]

Part No.

Part No.

[Mtl]

15 Fluid Cap

(2)

92750

92750

[A]

92773

92773

[SS]

92778

92778

[CI]

16 Manifold

(2)

92749

92749-1

[A]

92774

92774-1

[SS]

92777

92777-1

[CI]

HARDWARE OPTIONS
Carbon Steel

Stainless Steel

6661X0-, 1-, 2Item

Description (size)

6661XA-, B-, C-

Qty

Part No.

[Mtl]

Part No.

[Mtl]

(2)

92752

[C]

92775

[SS]

(8)

Y6-66-C

[C]

Y6-66-T

[SS]

27 Bolt (5/16” - 18 x 2-1/4”)

(4)

Y6-510-C

[C]

Y6-510-T

[SS]

29 Nut (5/16” - 18)

(20)

Y12-5-C

[C]

Y12-5-S

[SS]

32 Leg

(2)

92759

[C]

92759-1

[SS]

59 Bolt (5/16” - 18 x 2”)

(16)

93608

[C]

Y6-59-T

[SS]

5 Plate (air side)
26 Bolt (3/8” - 16 x 1-1/4”)

637155
ABRASION RESISTANT
CONVERSION KIT
Includes:

93266 (4) [SH] Seat
92757-8 (4) [U] Ball

COMMON PARTS
Item

Qty Part No.

[Mtl]

V 1 Rod

Description (size)

(1)

98720-1

[C]

L 2 “O” Ring (3/32” x 1” o.d.)

(1)

Y330-117

[B]

V 6 Plate (fluid side)

(2)

92775

[SS]

(2)

92752

[C]

(models 6661X0 only)

Item

Description (size)

Qty Part No.

[Mtl]

(2)

93065

[SS]

14 Screw (5/8” - 18 x 1-1/2”)

(2)

Y5-107-T

[SS]

43 Ground Lug (see page 7)

(1)

93004

[Co]

L 9 Washer (0.630” i.d.)

Service Note: Part no. 98931-T installation tool is available separately for use with items 1 and 2.
V “Smart Parts”, keep these items on hand in addition to the service kits for fast repair and reduction of down time.
Page 4 of 8

66615X-X-C (en)

PARTS LIST / 66615X-X-C FLUID SECTION
. TORQUE REQUIREMENTS ,

COLOR CODE
Material
Acetal
E.P.R.
Hytrel
Neoprene
Nitrile
Santoprene
PTFE
Polyurethane
Viton

Diaphragm
Color
N/A
Blue (--)
Cream
Green (--)
Black
Tan*
White
N/A
Yellow (--)

Ball
Color
Orange
Blue (S)
Cream
Green (S)
Red (S)
Tan
White
Red
Yellow (S)

(--) Stripe

(S) Dot

* See item 8 in inset below.

NOTE: DO NOT OVERTIGHTEN FASTENERS.
(14) Diaphragm screw, 65 - 70 ft lbs (88.1 - 94.9 Nm.).
(26) Bolts, 240 - 280 in. lbs (27.1 - 31.6 Nm).
(29) Nuts, 120 - 140 in. lbs (13.6 - 15.8 Nm).

LUBRICATION / SEALANTS

k Apply Key-Lube to all “O” rings, “U” Cups & mating parts.
z Apply LoctiteR 271 to threads.
U Apply anti-seize compound to threads and bolt and nut
flange heads which contact pump case when using stainless steel fasteners.

26 , U
FOR THE
AIR MOTOR SECTION
SEE PAGES 6 & 7

16

29 , U
1

2k
22

3k

19 k
21

15

5

Tab

59 U
7

k3

6

9

14 , z
27 U

32

22

16

21
19 k

26 , U
Figure 2
Santoprene 8
(Green when used as backer)

7 PTFE
(white)

1
Fluid
Side
Air
Side

3

8

5

Air
Side

10
Fluid
Side

66615X-X-C (en)

6

7
4

Tab
View for 6661XX-XX4-C (PTFE diaphragm) configuration only.

9

Cross Section View of Diaphragms

2

Torque Sequence
Page 5 of 8

PARTS LIST / 66615X-X-C AIR SECTION
n Indicates parts included in 637118-C Air Section Service Kit.
SERVICE KIT NOTE: Service Kit 637118-C is a general repair kit for all 1” and larger ARO diaphragm pump air motors. It contains extra “O” rings and
extra parts that may not be needed to service this model.
Item

Description (size)

101 Motor Body
n

Qty Part No.

[Mtl]

(66615X-X, 66617X-X)

(1)

94744

[A]

V 116 Spacer

(1)

92006

[Z]

(66616X-X, 66618X-X)

(1)

94742

[CI]

n

117 Gasket

(1)

92004

[B/Ny]

(2)

Y325-24

[B]

118 Pilot Rod

(1)

93309-2

[C]

102 “O” Ring (1/16” x 1-1/4” o.d.)

V 103 Sleeve
n

(1)

94528

[D]

104 Retaining Ring, TruArc (1-5/32” i.d.)

(2)

Y145-26

[C]

105 Screw / Lockwasher (1/4” - 20 x 5/8”)

(8)

93860

[C]

(models 6661X0-X, 6661X1-X, 6661X2-X)

Cap Screw (1/4” - 20 x 5/8”) (models

(8)

Y6-42-T

[SS]

6661XA-X, 6661XB-X, 6661X5C-X)

106 Lockwasher (1/4”) (models 6661XA-X,

(8)

Y14-416-T

[SS]

6661XB-X, 6661XC-X only)

n

Item

n

Description (size)

Qty Part No.

119 “O” Ring (1/8” x 3/4” o.d.)

(4)

93075

[U]

120 Spacer

(3)

115959

[Z]

121 Sleeve Bushing

(2)

98723-2

[Bz]

n

122 “O” Ring (3/32” x 9/16” o.d.)

(2)

94820

[U]

n

123 Screw (#8 - 32 x 3/8”)

(4)

Y154-41

[C]

126 Pipe Plug (1/2 - 14 P.T.F. x 17/32”)

(1)

Y227-5-L

[C]

127 90_ Street Elbow (3/4 - 14 N.P.T.)

(1)

Y43-5-C

[C]

128 Pipe Plug (1/8 - 27 P.T.F. x 1/4”)

(1)

Y227-2-L

[C]

(2)

94987

[SS]
[SS]

107 Plate

(2)

93707-1

[SS]

197 Button Head Screw (1/4” - 20 x 1/4”)

108 Gasket (with notch)

(1)

92878

[B/Ny]

198 Button Head Screw (1/4” - 20 x 3/8”)

(1)

94987-1

(1)

92011

[D]

201 Muffler

(1)

350-568

(2)

Y17-51-S

(1)

93706-1

V 109 Piston

(1)

Y186-51

[B]

231 Pipe Plug (1/4 - 18 N.P.T. x 0.41”) (models

V 111 Spool (models 66615X-X, 66617X-X)

(1)

92005

[A]

66616X-X and 66618X-X only)

(models 66616X-X, 66618X-X)

(1)

93047

[C]

(5)

92877

[Z]

n

110 “U” Cup (3/16” x 1-3/8” o.d.)

V 112 Washer (1.557” o.d.)
n

113 “O” Ring (small) (1/8” x 1-1/4” o.d.)

(5)

Y325-214

[B]

n

114 “O” Ring (large) (3/32” x 1-9/16” o.d.)

(6)

Y325-126

[B]

(4)

92876

[Z]

V 115 Spacer

n Key-Lube “O” Ring Lubricant
10 Pak of Key-Lube
n

PILOT VALVE DISASSEMBLY
1. Remove (104) retaining ring.
2. Remove (123) screws and (122) “O” rings.
3. Remove (118) piston rod, (121) sleeve bushing, (119) “O” rings and
(120) spacers from the (101) motor body.
4. Remove (103) sleeve and (102) “O” rings.

PILOT VALVE REASSEMBLY
1. Replace two (102) “O” rings if worn or damaged and reinstall (103)
sleeve.
2. Install one of the (121) sleeve bushings, (119) “O” rings, (120)
spacers and the remaining (121) bushing.
3. Carefully push (118) pilot rod into bushings etc. and retain on each
end with the two (122) “O” rings, retain with (123) screws.
4. Replace (104) retaining rings.

[SS]

(10) 637175

Service Kits include: Y212-101 (2) Screws (#10 - 32 x 1/4”) used on units mf’d between 8/90 and 4/92 to retain the pilot bushing.

AIR MOTOR SECTION SERVICE
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve.
GENERAL REASSEMBLY NOTES:
S Air Motor Section Service is continued from Fluid Section repair.
S Inspect and replace old parts with new parts as necessary. Look for
deep scratches on metallic surfaces, and nicks or cuts in “O” rings.
S Take precautions to prevent cutting “O” rings upon installation.
S Lubricate “O” rings with Key-Lube.
S Do not over-tighten fasteners, refer to torque specification block on
view.
S Re-torque fasteners following restart.

[Mtl]

MATERIAL CODE
[A] =
[B] =
[Bz] =
[C] =

Aluminum
Nitrile
Bronze
Carbon Steel

[CI] = Cast Iron
[D] = Acetal
[Ny] = Nylon

[SS] = Stainless Steel
[U] = Polyurethane
[Z] = Zinc

MAJOR VALVE DISASSEMBLY
1. Remove (107) plate (or leg depending on model), (108 and 117)
gaskets.
2. On the side opposite the air inlet, push on the inner diameter of (111)
spool. This will force the (109) piston out. Continue pushing the (111)
spool and remove. Check for scratches and gouges.
3. Reach into the air section (exhaust side) and remove (116) spacer,
(115) spacers, (113) “O” rings, (114) “O” rings, (112) washers, etc.
Check for damaged “O” rings.

MAJOR VALVE REASSEMBLY
1. Replace (112) washer, (114) “O” ring and (113) “O” ring onto (115)
spacer and insert etc.
NOTE: Be careful to orient spacer legs away from blocking internal ports.
2. Lubricate and carefully insert (111) spool.
3. Install (117) gasket and (107).
4. Lubricate and install (110) packing cup and insert (109) piston into
(air inlet side) cavity, the (110) packing cup lips should point outward.
5. Install (108) gasket and replace (107).

V “Smart Parts”, keep these items on hand in addition to the service kits for fast repair and reduction of down time.
Page 6 of 8

66615X-X-C (en)

PARTS LIST / 66615X-X-C AIR SECTION
117
111
115

105 ,

116

106

k 114

107

k 113
112

MAJOR VALVE
See cross section detail, figure 4.

IMPORTANT
BE CERTAIN TO ORIENT (115) SPACER LEGS
AWAY FROM BLOCKING INTERNAL PORTS
WHEN REASSEMBLING AIR SECTION.

101
z 197

Figure 3

104
H 123

121

197 z

43

102 k

z 198

103 k

106

104

. 105

126 g

107

PILOT VALVE
119 k

108
109

g 128

k 110

g 231

121
123 H
118 k

120
122 k
MAJOR VALVE CROSS SECTION DETAIL
109 110 k 112

114 k

113 k

115

111

201

116

127

. TORQUE REQUIREMENTS ,
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(105) 40 - 50 in. lbs (4.5 - 5.6 Nm).

Figure 4
k
H
z
g

66615X-X-C (en)

LUBRICATION / SEALANTS
Apply Key-Lube to all “O” rings, “U” Cups & mating parts.
Apply Loctite 262 to threads.
Apply Loctite 271 to threads.
Apply Loctite 572 to threads.

Page 7 of 8

TROUBLE SHOOTING
Product discharged from exhaust outlet.
S Check for diaphragm rupture.
S Check tightness of (14) diaphragm screw.
Air bubbles in product discharge.

S Check connections of suction plumbing.
S Check “O” rings between intake manifold and fluid caps.
S Check tightness of (14) diaphragm screw.

Low output volume, erratic flow or no flow.
S Check air supply.
S Check for plugged outlet hose.
S Check for kinked (restrictive) outlet material hose.
S Check for kinked (restrictive) or collapsed inlet material hose.
S Check for pump cavitation - suction pipe should be sized at least as
large as the inlet thread diameter of the pump for proper flow if high
viscosity fluids are being pumped. Suction hose must be a non-collapsing type, capable of pulling a high vacuum.
S Check all joints on the inlet manifolds and suction connections.
These must be air tight.
S Inspect the pump for solid objects lodged in the diaphragm chamber
or the seat area.

DIMENSIONAL DATA
(Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
Material Outlet
1-1/2 - 11-1/2 N.P.T.F. - 1 (66615X-X-C, 66616X-X-C)
Rp 1-1/2 (1-1/2 - 11 BSP parallel) (66617X-X-C, 66618X-X-C)

13-1/8” (333 mm)

18-3/8”

14-13/16” (376 mm)
11-1/2” (292 mm)

Air Inlet
1/2 - 14 N.P.T.F. - 1

(467 mm)

19-5/8”

7-5/8”

(498 mm)

(194 mm)
Air Exhaust Thread
3/4 - 14 N.P.T.F. - 1

2-3/4”
(70 mm)

10-3/4”
12 ”

1/2” Slot (14 mm)

(273 mm)

9” (229 mm)

(305 mm)

Material Inlet
1-1/2 - 11-1/2 N.P.T.F. - 1 (66615X-X-C, 66616X-X-C)
Rp 1-1/2 (1-1/2 - 11 BSP parallel) (66617X-X-C, 66618X-X-C)

Figure 5

PN 97999-96
Page 8 of 8

66615X-X-C (en)



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