AF044X-XX
AF046X-XX
OPERATOR’S MANUAL
RELEASED:
REVISED:
(REV. 02)
8-16-10
8-10-12
INCLUDING: SERVICE KITS, TROUBLESHOOTING, PARTS LIST,
DISASSEMBLY & REASSEMBLY.
4-1/4” AIR MOTORS
AF044X-XX (4” STROKE) and AF046X-XX (6” STROKE)
Also covers 637489 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 FOLLOWING MODELS
MODEL
AF0441-XX
AF0442-XX
AF0443-XX
AF0444-XX
AF0445-XX
AF0460-XX
SERVICE KITS
Use only genuine ARO® replacement parts to assure com-
patible pressure rating and longest service life.
637489 for general repair of all air motors.
GENERAL DESCRIPTION
DO NOT EXCEED MAXIMUM OPERATING
WARNING
PRESSURE AS INDICATED ON PUMP MODEL PLATE.
WARNING
REFER TO GENERAL INFORMATION SHEET
FOR ADDITIONAL SAFETY PRECAUTIONS AND IMPOR-
TANT INFORMATION.
AF0442-XX
This manual only covers the air motor section. It is one of
four documents which support an ARO pump. Replace-
ment copies of these forms are available upon request.
AF0441-XX
AF0443-XX
AF0444-XX
AF0445-XX
Pump Model Operator’s Manual.
General Information for Air Operated or Hydraulically
Operated Pumps.
Lower Pump End Operator’s Manual.
Air or Hydraulic Motor Operator’s Manual.
The 4-1/4” air motor is a general purpose power unit and
is used with many 2-ball, 4-ball, and chop check pumps.
It utilizes tie rod type construction for easy breakdown
and it connects to the various lower ends via tie rods for
easy operation. Consult pump model operator’s manual
for specific instructions.
MODEL DESCRIPTION CHART
AF04XX-01
A F 04 X X – XX
Air Motor Diameter
04 - 4 ¼”
Stroke Length
4 - 4”, 6 - 6”
AF0460-XX
Figure 1
Air Motor Base/Rod Combination
OPERATING AND SAFETY PRECAUTIONS
0 - Divorced pump base with quick coupled rod connection
1 - Divorced pump base with pinned coupled rod connection
2 - Coupled pump base with pinned coupled rod connection
3 - Coupled pump base with male threaded rod connection
4 - Coupled pump base with female threaded rod connection
5 - Coupled high pressure pump base with female threaded
DO NOT EXCEED MAXIMUM AIR INLET PRESSURE OF
150 P.S.I. (10.3 BAR) OR 75 CYCLES PER MINUTE.
CAUTION
High pressure equipment – Always dis-
connect air supply and relieve material pressure be-
fore attempting to service.
rod connection
(See Figure 4)
Air Motor Options
01 – Integrated On/Off Valve and Regulator
A ground lug is located on the air motor. This ground
lug allows proper grounding of the pump.
INGERSOLL RAND COMPANY LTD
209 NORTH MAIN STREET – BRYAN, OHIO 43506
© 2012
CCN 15330061
(800) 495-0276 FAX (800) 892-6276
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PARTS LIST / AF044X-XX & AF046X-XX
AIR MOTOR MODEL NO.
(size)
Item Description
Part No. (Qty) [Mtl]
(Stub)
Base & Bearing
Base & Bearing
Base & Bearing
** 65020
65023
(1)
(1)
[A]
[A]
101
102
(Stub)
65775
90074
(1)
(1)
[A]
[A]
[B]
[B]
[D]
(Stub)
Base
(1/8” x 1” O.D.)
O-Ring
O-Ring
Y325-210 (1)
Y325-220 (1)
(1/8” x 1 5/8” O.D.)
Bushing
Retainer
Guide
93310
93311
93312
93958
(1)
103
104
105
106
(1) [SS]
(1) [SS]
Plate
(1)
[A]
[C]
[C]
[C]
107 Lock Washer
108 Screw
(1/2” - 20)
Y14-616-C (4)
Y6-66-C
Y11-8-C
93897-1
96936
(4)
(4)
Nut
109
110
154
153
(1/2-14 N.P.T. X 9/16”)
Plug
(1) [PP]
(1) [Ef]
(1) [Ef]
Cylinder
Tube
112
114
121
96935
96874-1
96874-2
94046-1
94046-2
90103
(1)
(1)
(4)
(4)
(1)
(1)
[C]
[C]
[C]
[C]
[A]
[B]
�
152
151
(1/2” - 20 x 10 1/4”)
Bolt
Bolt
(1/2” - 20 x 8 1/4”)
Washer
151
152
153
154
(1/4” X 1 1/4” O.D.)
U-Cup
Y186-16
73986
Washer
Snap Ring
(1) [Br]
(1.456” O.D.)
Y147-131 (1)
[C]
--
101
67489
67490
67491
67492
67493
67494
(1)
(1)
(1)
(1)
(1)
(1)
--
Piston Assembly
(includes items 115, 117, 118,
119, & 120)
--
*203
--
--
Figure 3
--
Indicates where parts are used.
DISASSEMBLY OF AIR MOTOR
Items included in Service Kit (637489).
NOTE: Base styles and lower packings may vary from that
shown on the cover. Refer to model number in the chart
above.
For simplification of ordering and stocking, the Universal Ser-
vice Kit contains service parts that can be used for every size
of air motor. When repairing the motor, use only the parts that
are needed for that specific motor. Extra service parts from the
kit will remain after repair of the air motor.
NOTE: All threads are right hand.
1. Force the piston assembly up by pushing the (115) rod
toward the top of the air motor.
2. Remove the (155) muffler/(201) muffler assembly for
ease of disassembly.
3. Remove four (138) socket head screws from the (140)
head manifold. Remove the (140) head manifold by
pulling up and outward to remove from tubes (114) and
(137).
4. Remove (141) major gasket from the (140) head mani-
fold.
5. Remove tubes (114) and (137) by pulling upward.
6. Remove the four (113) O-rings from both tubes (114) and
(137).
MATERIAL CODE
[A]
[B]
[Br]
[Bz]
[C]
=
=
=
=
=
=
Aluminum
Buna Nitrile
Brass
Bronze
Carbon Steel
Ceramic
[D]
=
=
=
=
Acetal
Polypropylene
Stainless Steel
Epoxy - Fiberglass Filament Reinforced
[PP]
[SS]
[Ef]
[CK]
(continued on page 4)
AF044X-XX & AF046X-XX (en)
Page 3 of 8
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7. Align notch in (122) head plate with the port in (101) base
assembly and press the (122) head plate down until it is
seated against the (112) air cylinder. The (120) trip rod as-
sembly must lead thru the center of the (122) head plate.
8. Assemble the four (121) bolts thru the (122) head plate
and the (101) base assembly.
9. Assemble the four (109) nuts to (121) hex head bolts and
tighten per specified torque sequence and value.
10. Pull the (120) trip rod assembly as far out of the air mo-
tor assembly as possible, slide the (123) O-ring over the
(120) trip rod assembly and down into the gland found
in the (122) head plate.
11. Slide the (125) cap over the (120) trip rod assembly and
down into the bore found in the (122) head plate.
12. Slide the (129) snap ring first and the (130) washer sec-
ondly, onto the (120) trip rod assembly.
13. Slide the (132) driver onto the (120) trip rod assembly.
Align the hole of the (132) driver with the hole in the
(120) trip rod assembly and insert the (131) pin.
14. Assemble the (133) U-cup to the (134) spool. Take note
of the (133) U-cup lips should point down towards the
(122) head plate.
15. Slide the (134) spool onto the (120) trip rod assembly over
the (132) driver and insert the (130) washer behind it. Uti-
lizing snap ring pliers, assemble the (129) snap ring to the
internal groove found in the (134) spool. Be certain that
the (129) snap ring is fully engaged into the groove. Slide
the (134) spool downward into the bore of the (122) head
plate nesting on top of the (125) cap.
16. Lubricate the inside diameter of the (126) sleeve and
slide it onto the (134) spool and locating it into the (125)
cap. Take note that large taper on (126) Sleeve is to lo-
cate into (125) Cap.
DISASSEMBLY OF AIR MOTOR (CONT’D)
7. Remove the (142) valve plate and the (143) D-valve from
the (144) valve housing.
8. Remove the four (138) socket head screws to extract the
(150) pilot cover.
9. Remove the (148) pilot gasket from the (150) pilot cover.
10. Remove the (147) pilot valve plate and the (146) pilot
insert from the (144) valve housing.
11. Remove the two (145) socket head screws from the (144)
valve housing.
12. Remove the (144) valve housing by pulling straight up.
13. Remove the (124) O-ring, the (135) vent bushing, and the
(136) U-cup from the (144) valve housing.
14. Remove the (128) O-ring and the (126) sleeve from the
motor assembly by sliding it straight up.
15. Pull the (134) spool as far from the motor assembly as
possible to expose the under side of the spool itself.
16. Locate and remove the (129) snap ring from the (134)
spool utilizing snap ring pliers.
17. Lift to remove the (134) spool and remove the (133)
U-cup from it.
18. Slide the (131) pin to remove the (132) driver, (130)
washer, and (129) snap ring from the (120) trip rod as-
sembly.
19. Remove the four (109) nuts from (121) hex head bolts.
20. Remove the four (121) bolts from the (122) head plate
and the (101) base assembly.
21. Remove (122) head plate from the (112) air cylinder.
22. Remove the (111) O-ring, the (125) cap, and (123) O-ring
from the (122) head plate.
23. Pull upward on (112) air cylinder until (203) piston as-
sembly separates from the (101) base assembly. If, in this
step, the (203) piston assembly is not pulled from the
(101) base assembly, then remove it after removing the
(112) air cylinder.
24. If the (112) air cylinder and (203) piston assembly are
removed as one unit, then remove the (203) piston as-
sembly from the (112) air cylinder.
25. Remove the (116) O-ring from the (117) piston.
26. Remove the (111) O-ring from (101) base assembly.
27. For model AF0460-XX, remove (154) snap ring, (153)
washer, (152) U-cup, and (151) washer from the (101)
base assembly. For all other models remove the (102)
O-ring from the (101) base assembly.
17. Install the (128) O-ring onto the top gland of the (126)
sleeve.
18. Install the (136) U-cup, the (135) vent bushing into the
center bottom bore of the (144) valve housing. Take
note that the (136) U-cup lips must be facing up towards
the top of the (144) valve housing. Install the (124)
O-ring into the bottom recess gland of the (144) valve
housing.
19. Install the (144) valve housing to the motor assembly
by sliding the center bore onto the (134) spool and the
(126) sleeve. Take caution not to dislodge any of the
O-rings (124 & 128). Take note to align the large valve
pocket on the side of the (144) valve housing towards
the notch in the (122) head plate.
REASSEMBLY OF AIR MOTOR
1. Apply grease to all O-rings, U-cups, and other rubber
goods before installing.
2. For model AF0460-XX, install (151) washer, (152) U-cup,
(153) washer, and (154) snap ring into the (101) base as-
sembly. For all other models, install the (102) O-ring into
the (101) base assembly.
3. Install the (111) O-ring in the groove on the (101) base
assembly.
4. Install the (116) O-ring in the groove on the (117) piston.
5. Push (115) piston rod thru the (101) base assembly, be-
ing careful not to damage the lips of the (152) U-cup or
the (102) O-ring.
20. Install the two (145) socket head screws thru the (144)
valve housing and thread into the (122) head plate. The
(144) valve housing may need to be rotated slightly to
align the tapped holes. Tighten the (145) socket head
screws per specified torque value.
21. Install the (146) pilot insert, with pocket facing outward,
thru the (144) valve housing and into the (134) spool. The
(134) spool may need to be turned to orient its’ shallower
slot to face the smaller pocket of the (144) valve housing.
22. Install the (147) pilot valve plate, with identification
dimple facing outward, into the (144) valve housing cov-
ering the (146) pilot insert.
6. Lubricate the inside diameter of the (112) air cylinder
and slide it down over the (203) piston assembly and
onto the (101) air motor base assembly. (See Figure 2 on
page 2).
23. Install the (148) pilot gasket into the (150) pilot cover
and assemble to the (144) valve block using four (138)
socket head screws. Tighten to torque specifications.
24. Install the (143) D-valve, with pocket facing outward,
thru the (144) valve housing and into the (134) spool.
(continued on page 5)
Page 4 of 8
AF044X-XX & AF046X-XX (en)
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REASSEMBLY OF AIR MOTOR (CONT’D)
TROUBLE SHOOTING
25. Install the (142) major valve plate, with identification
dimple facing outward, into the (144) valve housing cov-
ering the (143) D-valve.
26. Install the four (113) O-rings onto both (114 & 137) tubes.
27. Loosely install the (137) tube into the bore in the (122)
head plate.
Air leakage out of main exhaust.
Damaged (141) track gasket. Replace (141) track gasket.
Worn (116) piston seal. Replace (116) piston seal.
Continual air leakage out (149) pilot exhaust.
Worn (136) “U” cup. Damaged (148) track gasket. Replace
(136) “U”cup and (148) track gasket.
28. Loosely install the (114) tube into the bore in the (101)
base assembly.
Air leakage out (149) pilot exhaust only during the down
stroke.
29. Install the (141) manifold gasket into the (140) mani-
fold and telescope onto both (114 & 137) tubes until
the (113) O-rings are seated. Fasten the (140) manifold
to the (144) valve block using four (138) socket head
screws. Tighten to torque specifications.
Worn (133) “U” cup. Rolled or damaged (128) “O” ring. Re-
place (133) “U”cup and (128) “O”ring.
Air leakage around (115) piston rod.
Worn or damaged (102) “O”ring or (152) “U”cup depend-
ing on motor model. Replace (102) “O”ring or (152) “U”
cup depending on motor model.
30. Install the (155) muffler/(201) muffler assembly.
VARIETIES OF BASE (101) AND PISTON ROD END (115)
TYPE -0-
Divorced Base, Quick Coupled Rod
65023 BASE and
TYPE -1-
TYPE -2-
Coupled Base, Pin Coupled Rod
65775 BASE and
Divorced Base, Pin Coupled Rod
65020 BASE with 93958 INSERT and
67494 PISTON ASSEMBLY
67489 PISTON ASSEMBLY
67493 PISTON ASSEMBLY
TYPE -3-
Coupled Base, Male Threaded Rod
65775 BASE and
TYPE -4-
TYPE -5-
Coupled Base, Female Threaded Rod
90074 BASE and
Coupled High Pressure Base,
Female Threaded Rod
65020 BASE and
67490 PISTON ASSEMBLY
67492 PISTON ASSEMBLY
67491 PISTON ASSEMBLY
Air Motor Base and Rod Combination
0 – Divorced pump base with quick coupled rod connection
1 – Divorced pump base with pin coupled rod connection
2 – Coupled pump base with pin coupled rod connection
3 – Coupled pump base with male threaded rod connection
4 – Coupled pump base with female threaded rod connection
5 – Coupled high pressure pump base with female threaded rod connection
Figure 4
AF044X-XX & AF046X-XX (en)
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Available Options for AF04XX-XX Air Motors
201
Optional
67445-1
Muffler Kit
202
Optional
67442
Self-Relieving
Ball Valve
Regulator / Shut-Off
(AF04XX-01)
Figure 5
Page 6 of 8
AF044X-XX & AF046X-XX (en)
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NOTES
AF044X-XX & AF046X-XX (en)
Page 7 of 8
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PN 97999-1466
Page 8 of 8
AF044X-XX & AF046X-XX (en)
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