OPERATOR’S MANUAL 66615X-X-C

INCLUDING: OPERATION, INSTALLATION & MAINTENANCE RELEASED: 5-31-88

REVISED: 5-11-15
1-1/2” DIAPHRAGM PUMP (REV. AE)
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 op-
tions.
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
Materialsee . . . . . “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) 66615X-XXX-C
Figure 1
[add 23 lbs (10.4 kgs) for cast iron air motor section] 1-1/2” DIAPHRAGM PUMP

Maximum Air Inlet Pressure . . . . . . . . 120 psig (8.3 bar)

Maximum Material Inlet Pressure. . . 10 psig (0.69 bar)
Maximum Outlet Pressure . . . . . . . . . 120 psig (8.3 bar) MODEL DESCRIPTION CHART
Maximum Flow Rate (flooded inlet) 90 gpm (340.7 lpm) 6661 X X X X X C
Displacement / Cycle @ 100 psig
Standard Diaphragm. . . . . . 0.64 gal. (2.42 lit.) CENTER BODY MATERIAL
5 - Aluminum, NPTF 7 - Aluminum, BSP
Composite PTFE Diaphgram 0.40 gal. (1.52 lit.) 6 - Cast Iron, NPTF 8 - Cast Iron, BSP
Maximum Particle Size . . . . . . . . . . . . . 1/4” dia. (6.4 mm)
FLUID CAP / MANIFOLD MATERIAL
Maximum Temperature Limits (diaphragm / ball / seat (Steel Hardware) (Stainless Steel Hardware)

material) 0 - Aluminum A - Aluminum

1 - Stainless Steel B - Stainless Steel
Acetal. . . . . . . . . . . . . . . . . . . 10º to 180º F (-12º - to 82º C) 2 - CastIron C - Cast Iron
E.P.R . . . . . . . . . . . . . . . . . . . -60º to 280º F (-51º - to 138º C)
Seat Material
Hytrel®. . . . . . . . . . . . . . . . . . -20º to 180º F (-29º - to 82º C) 1 - Aluminum 4 - Kynar PVDF
Kynar® PVDF. . . . . . . . . . . . . 10º to 200º F (-12º- to 93º C) 2 - 316Stainless Steel 5 - Carbon Steel
Neoprene . . . . . . . . . . . . . . . 0º to 200º F (-18º- to 93º C) 3 - Polypropylene 8 - 440 Stainless Steel

Nitrile . . . . . . . . . . . . . . . . . . . 10º to 180º F (-12º- to 82º C) Ball Material

Polypropylene. . . . . . . . . . . 35º to 175º F (2º- to 79º C) 1 - Neoprene 6 - Acetal
2 - Nitrile 8 - Polyurethane
Polyurethane. . . . . . . . . . . . 10º to 150º F (-12º- to 66º C) 3 - Viton A - Stainless Steel
4 - PTFE C - Hytrel
PTFE . . . . . . . . . . . . . . . . . . . 40º to 225º F (4º- to 107º C) 5 - E.P.R. E - Santoprene
Santoprene®. . . . . . . . . . . . . -40º to 225º F (-40º- to 107º C)
Diaphragm Material
Viton® . . . . . . . . . . . . . . . . . . -40º to 350º F (-40º- to 177º C) 1 - Neoprene 3 - Viton 9 - Hytrel
Dimensional Data. . . . . . . . . . . . see page 8 2 - Nitrile 5 - E.P.R. B - Santoprene
4 - PTFE / Santoprene 6 - Composite PTFE
Noise Level @ 70 psig- 60 cpm . . . . 80.5 dB(A)
FLUID SECTION SERVICE KIT SELECTION 6661XX X X X C
Tested with 350-568 muffler installed. EXAMPLE: MODEL # 666150-361-C 637124 X X
Fluid Section Service Kit # 637124-61 Ball Diaphragm
 The pump sound pressure levels published here have been updated to an Equivalent Con-
tinuous 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.

INGERSOLL RAND COMPANY LTD

209 NORTH MAIN STREET - BRYAN, OHIO 43506
 (800) 495-0276  FAX (800) 892-6276 © 2015 CCN 81660219
arozone.com
 OPERATING AND SAFETY PRECAUTIONS
READ, UNDERSTAND, AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.
WARNING HAZARDOUS MATERIALS. Can cause serious
EXCESSIVE AIR PRESSURE HAZARDOUS MATERIALS injury or property damage. Donot attempt to return
STATIC SPARK HAZARDOUS PRESSURE
a pump to the factory or service center that contains
hazardous material. Safe handling practices must comply
WARNING EXCESSIVE AIR PRESSURE. Can cause personal with local and national laws and safety code requirements.
injury, pump damage or property damage.  Obtain Material Safety Data Sheets on all materials from
 Do not exceed the maximum inlet air pressure as stated on the supplier for proper handling instructions. Obtain Mate-
the pump model plate. rial Safety Data Sheets on all materials from the supplier
 Be sure material hoses and other components are able to for proper handling instructions.
withstand fluid pressures developed by this pump. Check WARNING EXPLOSION HAZARD. Models containing
all hoses for damage or wear. Be certain dispensing device aluminum wetted parts cannot be used with
is clean and in proper working condition. 1,1,1-trichloroethane, methylene chloride or other
WARNING STATIC SPARK. Can cause explosion resulting halogenated hydrocarbon solvents which may react
in severe injury or death. Ground pump and pumping and explode.
system.  Check pump motor section, fluid caps, manifolds and all
 Sparks can ignite flammable material and vapors. wetted parts to assure compatibility before using with sol-
 The pumping system and object being sprayed must be vents of this type.
grounded when it is pumping, flushing, recircula ing or CAUTION Verify the chemical compatibility of the pump
spraying flammable materials such as paints, solvents, lac- wetted parts and the substance being pumped, flushed
quers, etc. or used in a location where surrounding atmo- or recirculated. Chemical compatibility may change with
sphere is conducive to spontaneous combustion. Ground temperature and concentration of the chemical(s) within
the dispensing valve or device, containers, hoses and any the substances being pumped, flushed or circulated.
object to which material is being pumped. For specific fluid compatibility, consult the chemical
 Use the pump grounding screw terminal provided. Use ARO manufacturer.
®part no. 66885-1 ground kit or connect a suitable ground CAUTION Maximum temperatures are based on
wire (12 ga. minimum) to a good earth ground source. mechanical stress only. Certain chemicals will significantly
 Secure pump, connections and all contact points to avoid reduce maximum safe operating temperature. Consult
vibration and generation of contact or static spark. the chemical manufacturer for chemical compatibility and
 Consult local building codes and electrical codes for spe- temperature limits. Refer to PUMP DATA on page 1 of this
cific grounding requirements. manual.
 Aftergrounding, periodically verify continuity of electrical- CAUTION Be certain all operators of this equipment
path to ground. Test with an ohmmeter from each compo- have been trained for safe working practices, understand
nent (e.g., hoses, pump, clamps, container, spray gun, etc.) it’s limitations, and wear safety goggles / equipment when
to ground to ensure continuity. Ohmmeter should show 0.1 required.
ohms or less. CAUTION Do not use the pump for the structural
 Submerse the outlet hose end, dispensing valve or device support of the piping system. Be certain the system
in the material being dispensed if possible. (Avoid free components are properly supported to prevent stress on
streaming of material being dispensed.) the pump parts.
 Use hoses incorporating a static wire.  Suction and discharge connections should be flexible con-
 Use proper ventilation. nections (such as hose), not rigid piped, and should be com-
 Keep inflammables away from heat, open flames and patible with the substance being pumped.
sparks. CAUTION Prevent unnecessary damage to the pump.
 Keep containers closed when not in use. Do not allow pump to operate when out of material for
 WARNING Pump exhaust may contain contaminants. long periods of time.
Can causesevere injury. Pipe exhaust away from work are a  Disconnect air line from pump when system sits idle for
and personnel. long periods of time.
 In the event of a diaphragm rupture, material can be forced CAUTION Use only genuine ARO replacement parts to
out of the air exhaust muffler. assure compatible pressure rating and longest service life.
 Pipe the exhaust to a safe remote location when pumping NOTICE Replacement warning labels are available
hazardous or inflammable materials. upon request: “Static Spark” (93616-1) & “Diaphragm
 Use a grounded 3/4” minimum i.d. hose between the pump Rupture” (93122).
and the muffler.
WARNING HAZARDOUS PRESSURE. Can result in serious WARNING = Hazards or unsafe practices which
injury or property damage. Do not service or clean pump, could result in severe personal injury,
hoses or dispensing valve while the system is pressurized. death or substantial property damage.
 Disconnect air supply line and relieve pressure from the CAUTION = Hazards or unsafe practices which
system by opening dispensing valve or device and / or could result in minor personal in-
carefully and slowly loosening and removing outlet hose or jury, product or property damage.
piping from pump.
NOTICE = Important installation, operation or
maintenance information.

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66615X-X-C (en)
 GENERAL DESCRIPTION FLUID SECTION DISASSEMBLY
The ARO diaphragm pump offers high volume delivery even at 1. Remove top manifold(s).
low air pressure and a broad range of material compatibility 2. Remove (22) balls, (19) “O” rings and (21) seats.
options available. Refer to the model and option chart. ARO 3. Remove (15) fluid caps.
pumps feature stall resistant design, modular air motor / NOTE: Only PTFE diaphragm models use a primary dia-
fluid sections. Air operated double diaphragm pumps utilize phragm (7) and a backup diaphragm (8). Refer to the auxiliary
a pressure differential in the air chambers to alternately cre- view in the Fluid Section illustration.
ate suction and positive fluid pressure in the fluid chambers, For 6661XX-XX6-C:
valve checks ensure a positive flow of fluid. Pump cycling will 4. Remove (7)diaphragm,(5)washers and (30)shims.
begin as air pressure is applied and it will continue to pump For other models:
and keep up with the demand. It will build and maintain line 5. Remove the (14) screws, (6) washers, (7) or (7 / 8)
pressure and will stop cycling once maximum line pressure is diaphragms and (5) washers.
reached (dispensing device closed) and will resume pumping 6. Remove (3) “O” rings.
as needed. NOTE: Do not scratch or mar the surface of (1) diaphragm
rod.
AIR AND LUBE REQUIREMENTS
EXCESSIVE AIR PRESSURE. Can cause personal injury, pump FLUID SECTION REASSEMBLY
damage or property damage.  Reassemble in reverse order.
 A filter capable of filtering out particles larger than 50  Clean and inspect all parts. Replace worn or damaged
microns should be used on the air supply. There is no lu- parts with new parts as required.
brication required other than the “O” ring lubricant which  Lubricate (1) diaphragm rod and (2) “O” ring with Key-
is applied during assembly or repair. Lube “O” ring lube.
 If lubricated air is present,makesure that it is compatible  Use AROpn / 98931-T bullet (installation tool) to aid in
with the “O” rings and seals in the air motor section of the installation of (2) “O” ring on (1) diaphragm rod.
pump. For 6661XX-XX6-C:
 Attach a regulated airline to the pump inlet; gradually
OPERATING INSTRUCTIONS increasing the air pressure (6-8 psi) to check which side of
 Always flush the pump with a solvent compatible with the pump with air blowing out, and then shut down the
the material being pumped if the material being pumped air supplier.
is subject to “setting up” when not in use for a period of  Fasten (7) diaphragm with (5) washer into (1) diaphragm
time. rod, and insert them into (101) Center body from the
 Disconnect the air supply from the pump if it is to be inac- chamber identified with blowing air in the previous step.
tive for a few hours.  Install (15) fluid cap.
 The outlet material volume is governed not only by the  Thread the other side of (7) diaphragm with (5) washer
air supply, but also by the material supply available at the into (1) diaphragm rod, but do not tighten it.
inlet. The material supply tubing should not be too small  Record the angle for the misalignment between (7) dia-
or restrictive. Be sure not to use hose which might co phragm hole and (101) center body holes, then unthread
lapse. the (7) diaphragm and place proper Qty. of (30) shims
 When the diaphragm pump is used in a forced-feed between (5) washer and (1) diaphragm rod.
(flooded inlet) situation, it is recommended that a “Check  Attach a regulated airline to the pump inlet, gradually
Valve” be installed at the air inlet. increasing the air pressure (6-8 psi) until the diaphragm
 Secure the diaphragm pump legs to a suitable surface to shift to the other site, shut down the air supply.
ensure against damage by vibration.  Install the second (15) fluid cap.
NOTE: For details, refer to service kits manual 48495949.
MAINTENANCE For other models:
 Be certain (7) or (7 / 8) diaphragm(s) align properly with
Refer to the part views and descriptions as provided on pages (15) fluid caps before making final torque adjustments on
4 through 7 for parts identification and service kit informa- bolt and nuts to avoid twisting the diaphragm.
tion.  For models with PTFE diaphragms: Item (8) Santoprene
 Certain ARO “Smart Parts” are indicated which should be diaphragm is installed with the side marked “AIR SIDE”
available for fast repair and reduction of down time. towards the pump center body. Install the PTFE
 Service kits are divided to service two separate diaphragm diaphragm with the side marked “FLUID SIDE” towards the
pump functions: 1. AIR SECTION, 2. FLUID SECTION. The fluid cap.
FLUID SECTION is divided further to match typical part  Check all torque settings after pump has been re-started
MATERIAL OPTIONS. and run a while.
 Provide a clean work surface to protect sensitive internal
moving parts from contamination from dirt and foreign
matter during service disassembly and reassembly.
 Keep good records of service activity and include pump
in preventive maintenance program.
 Before disassembling, empty captured material in the
outlet manifold by turning the pump upside down to
drain material from the pump.
 Viton® and Hytrel® are registered trademarks of the DuPont Company. Kynar® is a registered trademark of Penwell Corp. ARO® is a registered trademark of Ingersoll Rand Company 
 Santoprene® is a registered trademark of Monsanto Company, licensed to Advanced Elastomer Systems, L.P. Key-Lube® is a registered trademark of Key Industries 

66615X-X-C (en)������������
Page  of 8
 PARTS LIST / 66615X-X-C FLUID SECTION
 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. MATERIAL CODE
[A] = Aluminum
SEAT OPTIONS BALL OPTIONS [B] = Nitrile
6661XX-XXX-C 6661XX-XXX-C [C] = Carbon Steel
[CI] = Cast Iron
“21”   “22” (1-1/4” dia.) [Co]= Copper
[CP] = Composite PTFE
-XXX Seat Qty [Mtl] -XXX Ball Qty [Mtl] -XXX Ball Qty [Mtl] [D] = Acetal
[E] = E.P.R.
-1XX 92760 (4) [A] -X1X 92757-1 (4) [N] -X8X 92757-8 (4) [U] [H] = Hytrel
-2XX 92776 (4) [SS] -X2X 92757-2 (4) [B] -XAX 94804 (4) [SS] [K] = Kynar PVDF
-3XX 92924 (4) [P] -X3X 92757-3 (4) [V] -XCX 92757-C (4) [H] [P] = Polypropylene
[SH] = Hard Stainless Steel
-4XX 94514 (4) [K] -X4X 92757-4 (4) [T] -XEX 92757-A (4) [Sp] [Sp] = Santoprene
-5XX 95676 (4) [C] -X5X 92757-5 (4) [E] [SS] = Stainless Steel
-8XX 93266 (4) [SH] -X6X 92757-6 (4) [D] [T] = PTFE
[U] = Polyurethane
[V] = Viton

DIAPHRAGM OPTIONS 6661XX-XXX-C

  SERVICE KIT
 “7”  “8”  “3” (1/16” x 3/4” o.d.)  “19”
-XX = (Ball)
-XXX -XX = (Diaphragm) Diaphragm [Qty] [Mtl] Diaphragm [Qty] [Mtl] "O” Ring [Qty] [Mtl] "O” Ring [Qty] [Mtl]
-XX1 637124-X1 92755-1 (2) [N] --- [B] Y325-16 (4) [B] Y325-230 (4) [B]
-XX2 637124-X2 92755-2 (2) [B] --- [B] Y325-16 (4) [B] Y325-230 (4) [B]
-XX3 637124-X3 92755-3 (2) [V] --- [T] 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] --- [T] Y328-16 (4) [T] 92761 (4) [E]
-XX6 48496806 48490064 (2) [CP] --- --- --- --- --- Y220-230 (4) [T]
-XX9 637124-X9 94615-9 (2) [H] --- [T] Y328-16 (4) [T] Y327-230 (4) [V]
-XXB 637124-XB 94615-A (2) [Sp] --- [T] Y328-16 (4) [T] 92761 (4) [E]

WETTED PARTS OPTIONS 6661XX-XXX-C

Aluminum Stainless Steel Cast Iron
6661X0-X, 6661XA-X 6661X1-X, 6661XB-X 6661X2-X, 6661XC-X
NPTF BSP NPTF BSP NPTF BSP
Item Description (Size) 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 6661XX-XXX-C

Carbon Steel Stainless Steel
Item Description (Size) Qty 6661X0-, 1-, 2- 6661XA-, B-, C
Part No. [Mtl] Part No. [Mtl]
Plate (air side) (6661XX-XX6-C) (2) 48496673 [C] 48496673 [SS] 637155
5 ABRASION RESISTANT
(Other models) (2) 92752 [C] 92775 [SS]
CONVERSION KIT
26 Bolt (3/8” - 16 x 1-1/4”) (8) Y6-66-C [C] Y6-66-T [SS] Includes:
93266 (4) [SH] Seat
27 Bolt (5/16” - 18 x 2-1/4”) (4) Y6-510-C [C] Y6-510-T [SS]
92757-8 (4) [U] Ball
29 Nut (5/16” - 18) (20) Y12-5-C [C] Y12-5-S [SS]
32 Leg (2) 92759 [C] 92759-1 [SS]
Bolt (5/16” - 18 x 2”)(6661XX-XX6-C) (16) 47512837001 [C] 47510437001 [SS]
59
(Other models) (16) 93608 [C] Y6-59-T [SS]
COMMON PARTS
Item Description (size in inches) Qty Part No. [Mtl] Item Description (Size in inches) Qty Part No. [Mtl]
1 Rod (6661XX-XX6-C) (1) 48489819 [C]
9 Washer (0.630” i.d.) (2) 93065 [SS]
(other models) (1) 98720-1 [C]
14 Screw (5/8” - 18 x 1-1/2”) (2) Y5-107-T [SS]
 2 ‘‘O” Ring (3/32” x 1” o.d.) (1) Y330-117 [B]
43 Ground Lug (see page 7) (1) 93004 [Co]
6 Plate (fluid side) (2) 92775 [SS]
30 Shim (6661XX-XX6-C) () 48499875 # [C]
(models 6661X0 only) (2) 92752 [C]
Service Note: Part no. 98931-T installation tool is available separately for use with items 1 and 2.
 The quantity is between 0 to 5, shims are not shown in the exploded view. # For service, shim pack 48499339 can be purchased. Refer to service kits manual 48495949
for details.
 "Smart Parts” keep these items on hand in addition to the Service Kits for fast repair and
reduction of down time.
 For 6661XX-XX6-C, on the fluid side, washer (6), (9) and screw (14) are not needed.

Page  of 8 ���������������
66615X-X-C (en)
 PARTS LIST / 66615X-X-C FLUID SECTION
COLOR CODE . TORQUE REQUIREMENTS ,
Diaphragm Ball NOTE: DO NOT OVERTIGHTEN FASTENERS.
Material color Color
Acetal N/A Orange (14) Diaphragm screw, 65 - 70 ft lbs (88.1 - 94.9 Nm.).
E.P.R. Blue(-) Blue(•) (26) Bolts, 240 - 280 in. lbs (27.1 - 31.6 Nm).
Hytrel Cream Cream (29) Nuts, 120 - 140 in. lbs (13.6 - 15.8 Nm).
Neoprene Green(-) Green(•)
Nitrile
Santoprene
Black
Tan�
Red(•)
Tan
LUBRICATION / SEALANTS
PTFE White White k Apply Key-Lubetoall“O”rings,“U” Cups & mating parts.
Polyurethane N/A Red z Apply Loctite 271 to threads
Viton Yellow(-) Yellow(•) U Apply anti-seize compound to threads and bolt and nut
(-)Stripe (•)Dot flange heads which contact pump case when using
�See item 8 in inset below. stainless steel fasteners.
26 , U
16 FOR THE
29 , U AIR MOTOR SECTION
SEE PAGES 6&7
1 2k

3k 22
19k
21

15

5 Tab

59U
7 6 k3 9 14, z
27U

32 22

16 21
19k
26, U
Figure 2
Santoprene 8
(Green when used as backer)
7 PTFE
(white)

1 3
Fluid Side
8 5
Air Side Air Side

10 9

Fluid Side
6 7

Tab 4 2

View for 6661XX-XX4 -C (PTFEdiaphragm) configurationonly.

TorqueSequence
Cross Section View of Diaphragms

66615X-X-C (en)������������
Page  of 8
 PARTS LIST / 66615X-X-C AIR SECTION
 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 other
parts that may not be needed to service this model.
Item Description (size) Qty Part No. [Mtl] Item Description (size) Qty Part No. [Mtl]
Motor Body(66615X-X, 66617X-X) (1) 94744 [A]  115 Spacer (4) 92876 [Z]
101
(66616X-X, 66618X-X) (1) 94742 [CI]  116 Spacer (1) 92006 [Z]
 102 ‘‘O” Ring(1/16” x 1-1/4” o.d.) (2) Y325-24 [B]  117 Gasket (1) 92004 [B/Ny]
 103 Sleeve (1) 94528 [D] 118 Pilot Rod (1) 93309-2 [C]

 104 Retaining Ring, TruArc (1-5/32” i.d.) (2) Y145-26 [C]

 119 “O” Ring (1/8” x 3/4” o.d.) (4) 93075 [U]
120 Spacer (3) 115959 [Z]
Screw / Lockwasher (1/4” - 20 x 5/8”) (8) 93860 [C]
105 (models 6661X0-X, 6661X1-X, 6661X2-X) 121 Sleeve Bushing (2) 98723-2 [Bz]
6661XA-X, 6661XB-X, 6661X5C-X) (8) Y6-42-T [SS]  122 “O” Ring (3/32” x 9/16” o.d.) (2) 94820 [U]
106 Lockwasher  123 Screw (#8 - 32 x 3/8”) (4) Y154-41 [C]
(1/4”) (models 6661XA-X,
6661XB-X, 6661XC-X only)
(8) Y14-416-T [SS]
126 Pipe Plug (1/2 - 14 P.T.F. x 17/32”) (1) Y227-5-L [C]
107 Plate (2) 93707-1 [SS]
127 90º Street Elbow (3/4 - 14 NPTF) (1) Y43-5-C [C]
 108 Gasket (with notch) (1) 92878 [B/Ny]
128 Pipe Plug (1/8 - 27 P.T.F. x 1/4”) (1) Y227-2-L [C]
 109 Piston (1) 92011 [D]
197 Button Head Screw (1/4” - 20 x 1/4”) (2) 94987 [SS]
 110 “U” Cup (3/16” x 1-3/8” o.d.) (1) Y186-51 [B] 198 Button Head Screw (1/4” - 20 x 3/8”) (1) 94987-1 [SS]
Spool (models 66615X-X, 66617X-X) (1) 92005 [A] 201 Muffler (1) 350-568
 111
(1) 93047 [C]
231 Pipe Plug
(models 66616X-X, 66618X-X) (1/4 - 18 NPTF x 0.41”) (models
66616X-X and 66618X-X only)
(2) Y17-51-S [SS]
 112 Washer (1.557” o.d.) (5) 92877 [Z]
 Key-Lube “O” Ring Lubricant (1) 93706-1
 113 “O” Ring (small) (1/8” x 1-1/4” o.d.) (5) Y325-214 [B]
10 Pack of Key-Lube 637175
 114 “O” Ring (large) (3/32” x 1-9/16” o.d.) (6) Y325-126 [B]

AIR MOTOR SECTION SERVICE MATERIAL CODE

[A] = Aluminum [CI] = Cast Iron [SS] = Stainless Steel
Service is divided into two parts - 1. Pilot Valve, 2. Major Valve. [B] = Nitrile [D] = Acetal [U]= Polyurethane
GENERAL REASSEMBLY NOTES: [Bz] = Bronze
[C] = Carbon Steel
[Ny] = Nylon [Z] = Zinc

 Air Motor Section Service is continued from Fluid Section

repair. MAJOR VALVE DISASSEMBLY
 Inspect and replace old parts with new parts as
necessary. Look for deep scratches on metallic surfaces, 1. Remove (107) plate (or leg depending on model), (108
and nicks or cuts in “O” rings. and 117) gaskets.
 Take precautions to prevent cutting “O” rings upon 2. On the side opposite the air inlet, push on the inner di-
installation. ameter of (111) spool. This will force the (109) piston out.
 Lubricate “O” rings with Key-Lube. Continue pushing the (111) spool and remove. Check for
 Do not over-tighten fasteners, refer to torque specifica- scratches and gouges.
tion block on view. 3. Reach into the air section (exhaust side) and remove
 Make sure to torque all fasteners following restart. (116) spacer, (115) spacers, (113) “O” rings, (114) “O” rings,
(112) washers, etc. Check for damaged “O” rings.
PILOT VALVE DISASSEMBLY
MAJOR VALVE REASSEMBLY
1. Remove (104) retaining ring.
2. Remove (123) screws and (122) “O” rings. 1. Replace (112) washer, (114) “O” ring and (113) “O” ring
3. Remove (118) piston rod, (121) sleeve bushing, (119) “O” onto (115) spacer and insert etc.
rings and (120) spacers from the (101) motor body. NOTE: Be careful to orient spacer legs away from block-
4. Remove (103) sleeve and (102) “O” rings. ing internal ports.
2. Lubricate and carefully insert (111) spool.
PILOT VALVE REASSEMBLY 3. Install (117) gasket and (107).
4. Lubricate and install (110) packing cup and insert (109)
1. Replace two (102) “O” rings if worn or damaged and re- piston into (air inlet side) cavity, the (110) packing cup
install (103) sleeve. lips should point outward.
2. Install one of the (121) sleeve bushings, (119) “O” rings, 5. Install (108) gasket and replace (107).
(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.

 “Smart Parts” Keep these items on hand in addition to the Service Kits for fast repair and reduction of down time.

Page  of 8 ���������������
66615X-X-C (en)
 PARTS LIST / 66615X-X-C AIR SECTION
117
111 105 �
115 116
106
�114
107
�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

�197 Figure 3

104

�123

121
197�
43
102�
�198
103�

106 104

�105
126 �
107

PILOT VALVE
119� 121
108
123 �
109 128
�

118�
�110 231
�

120
122�
MAJOR VALVE CROSS SECTION DETAIL
201
109 110� 112 114� 113 � 115 111 116
127

� TORQUE REQUIREMENTS �
NOTE: DO NOT OVERTIGHTEN FASTENERS.
(105) 40 - 50 in. lbs (4.5 - 5.6 Nm).
Figure 4
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.
�

66615X-X-C (en)������������
Page  of 8
 TROUBLE SHOOTING
Product discharged from exhaust outlet. Low output volume, erratic flow, or no flow.
 Check for diaphragm rupture.  Check air supply.
 Check tightness of (14) diaphragm screw.  Check for plugged outlet hose.
 Check for kinked (restrictive) outlet material hose.
Air bubbles in product discharge.  Check for kinked (restrictive) or collapsed inlet material
 Check connections of suction plumbing. hose.
 Check “O” rings between intake manifold and fluid caps.  Check for pump cavitation - suction pipe should be sized
 Check tightness of (14) diaphragm screw. 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.
 Check all joints on the inlet manifolds and suction con-
nections. These must be air tight.
 Inspect the pump for solid objects lodged in the dia-
phragm 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 NPTF - 1 (66615X-X-C, 66616X-X-C)
Rp 1-1/2 (1-1/2 - 11 BSP parallel)(66617X-X-C,66618X-X-C)
14-13/16” (376mm)
13-1/8” (333mm)
11-1/2” (292mm)

18-3/8” Air Inlet

(467mm) 1/2-14NPTF-1

19-5/8”
7-5/8” (498mm)
(194mm)

Air Exhaust Thread

2-3/4”
3/4-14NPTF-1
(70mm)

10-3/4” (273 mm) 1/2”Slot (14mm)

12” (305 mm) 9” (229mm)

Material Outlet
1-1/2 - 11-1/2 NPTF - 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  of 8 66615X-X-C (en)