AF064X-XX

OPERATOR’S MANUAL AF066X-XX

INCLUDING: SERVICE KITS, TROUBLESHOOTING, PARTS LIST, RELEASED: 8-16-10
DISASSEMBLY AND REASSEMBLY. REVISED: 10-28-23
(REV: J)
6” AIR MOTORS
AF064X-XX (4” STROKE) and AF066X-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
AF0645-XX AF0660-XX

SERVICE KITS
y Use only genuine ARO® replacement parts to assure com-
patible pressure rating and longest service life.
y 637489 for general repair of all air motors.
GENERAL DESCRIPTION
WARNING DO NOT EXCEED MAXIMUM OPERATING
PRESSURE AS INDICATED ON PUMP MODEL PLATE.
WARNING REFER TO GENERAL INFORMATION SHEET
FOR ADDITIONAL SAFETY PRECAUTIONS AND IM- AF06XX-01
PORTANT INFORMATION. AF0645-XX
y 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.
 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.
y The 6” 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

A F 06 X X – XX
Air Motor Diameter AF0660-XX Figure 1
06 - 6”
OPERATING AND SAFETY PRECAUTIONS
Stroke Length
4 - 4”, 6 - 6” y DO NOT EXCEED MAXIMUM AIR INLET PRESSURE OF
Air Motor Base/Rod Combination 150 PSI (10.3 BAR) OR 75 CYCLES PER MINUTE.
0 - Divorced pump base with quick coupled rod connection CAUTION High pressure equipment – Always dis-
5 - Coupled high pressure pump base with female threaded connect air supply and relieve material pressure be-
rod connection (See Figure 4)
fore attempting to service.
Air Motor Options
y A ground lug is located on the air motor. This ground
01 – Integrated On/Off Valve and Regulator
lug allows proper grounding of the pump.

INGERSOLL RAND COMPANY INC

209 NORTH MAIN STREET – BRYAN, OHIO 43506
 (800) 495-0276  FAX (800) 892-6276 © 2023 CCN 15330079
arozone.com
 PARTS LIST / AF064X-XX AND AF066X-XX
Item Description (Qty) Part No. [Mtl] 138 149
111 O-Ring (1/8” X 6” OD) (2) Y325-256 [B]
148
113 O-Ring (1/16” X 13/16” OD) (4) Y325-17 [B]
145
*115 Rod (1) [SS]
144
116 O-Ring (3/16” X 6” OD) (1) Y325-433 [B] 150
143
*117 Piston (1) [A] 147 142
*118 O-Ring (1/16” X 11/16” OD) (1) [B] 146 141

*119 Bushing (1) [C]

*120 Trip Rod Assembly (1) [A] 155
122 Head Plate (1) 96860 [A]
138
121 140
123 O-Ring (3/32” X 1/2” OD) (1) Y325-109 [B]
127
124 O-Ring (1/16” X 2” OD) (1) Y325-32 [B]
113
125 Cap (1) 96897 [D] 137
122
126 Sleeve (1) 96901 [Br/A] 113
136
127 Ground Lug (1) 96878 [Bz]
111 135
128 O-Ring (1/16” X 1 11/16” OD) (1) 96917 [B] 113
116 134
129 Snap Ring (1.180” OD) (1) Y147-7 [C]
130 Washer (1) 96894 [C] 114
133
131 Pin (1) 96895 [C] 117 131
113 132
132 Driver (1) 96868 [C] 119 130
*203 129
133 U-Cup (3/16” X 1 1/2” OD) (1) 96908 [B] Not User 118
128
Serviceable
134 Spool (1) 96875 [A]
126
135 Vent Bushing (1) 96896 [D] 120
125
136 U-Cup (5/32” X 1 3/8” OD) (1) 96907 [B]
124
137 Tube (1) 96870 [C]
123
138 Socket Head Screw (5/16”-18 X 1”) (8) Y99-52-S [SS] 115
140 Head Manifold (1) 96855 [A]
141 Major Gasket (1) 96900 [B]
142 Valve Plate (1) 96884 [CK]
112
143 D-Valve (1) 96889-2 [D]
144 Valve Housing (1) 96864 [A]
145 Socket Head Screw
(5/16”-18 X 4 1/2”)
(2) Y99-516-S [SS] 102
146 Pilot Insert (1) 96882 [D] 111
147 Pilot Valve Plate (1) 96883 [CK]
148 Pilot Gasket (1) 96899 [B] 110
101
149 Vent Plug (1) 96906 [D]
150 Pilot Cover (1) 96865 [A]
155 Muffler (1) 96916 [C] TORQUE
201 Muffler Kit (Optional, See Fig. 5) (1) 67445-2 [C] 109 SEQUENCE

Regulator / Shut-Off (Optional, 3

202 (1) 67442
See Fig. 5)
2
 Lubriplate
(1/4 oz.)
FML-2 Grease Packet (2) 94276

 TORQUE REQUIREMENTS 
NOTE: DO NOT OVERTIGHTEN FASTENERS. 1
Tighten (109 and 121) to 10-15 ft-lbs (13.6-20.3 Nm)
Tighten (138 and 145) to 50-60 in-lbs (5.6-6.8 Nm)
4
LUBRICATION / SEALANTS
 NOTE: Lubricate with Grease (ARO p/n 94276). Figure 2

Page 2 of 8 AF064X-XX and AF066X-XX (en)

 PARTS LIST / AF064X-XX AND AF066X-XX
AIR MOTOR MODEL NO.
Item Description (size) Part No. (Qty) [Mtl] AF0645-XX AF0660-XX
Base & Bearing (Stub)** 67488 (1) [A]
101
Base & Bearing 67462 (1) [A]
102 O-Ring (1/8” x 1” OD) Y325-210 (1) [B]
109 Nut (1/2” - 20) Y11-8-C (4) [C]
110 Plug (1/2-14 N.P.T. X 9/16”) 11481-25 (1) [PP]
96938 (1) [Ef]
112 Cylinder
96937 (1) [Ef]
96880-1 (1) [C]
114 Tube
96880-2 (1) [C]
Bolt (1/2” - 20 x 10 1/4”) 94046-1 (4) [C]
121
Bolt (1/2” - 20 x 8 1/4”) 94046-2 (4) [C]
151 Washer 90103 (1) [A]
152 U-Cup (1/4” X 1 1/4” OD) Y186-16 (1) [B]
153 Washer 73986 (1) [Br]
154 Snap Ring (1.456” OD) Y147-131 (1) [C] 154
Piston Assembly 67495 (1) --
*203 (includes items 115, 117, 118,
119, & 120) 67496 (1) -- 153
 Indicates where parts are used.
 Items included in Service Kit (637489)
152
NOTE: Base styles and lower packings may vary from that
shown on the cover. Refer to model number in the chart 151
above.
For simplification of ordering and stocking, a Y325-210 “O”
ring, and a Y186-16 “U” cup will be included in 637474 ser-
vice kit. When repairing the motor, use only the one that is
needed.
All of the service parts are the same for all motors except the
lower piston rod packing.
101
MATERIAL CODE
[A] = Aluminum [D] = Acetal
[B] = Buna Nitrile [PP] = Polypropylene
[Br] = Brass [SS] = Stainless Steel
[Bz] = Bronze [Ef] = Epoxy - Fiberglass Filament Reinforced
[C] = Carbon Steel
[CK] = Ceramic Figure 3

DISASSEMBLY OF AIR MOTOR

7. Remove the (142) valve plate and the (143) D-valve from
NOTE: All threads are right hand. the (144) valve housing.
1. Force the piston assembly up by pushing the (115) rod 8. Remove the four (138) socket head screws to extract the
toward the top of the air motor. (150) pilot cover.
2. Remove the (155) muffler/(201) muffler assembly for 9. Remove the (148) pilot gasket from the (150) pilot cover.
ease of disassembly. 10. Remove the (147) pilot valve plate and the (146) pilot
3. Remove four (138) socket head screws from the (140) insert from the (144) valve housing.
head manifold. Remove the (140) head manifold by 11. Remove the two (145) socket head screws from the (144)
pulling up and outward to remove from tubes (114) and valve housing.
(137). 12. Remove the (144) valve housing by pulling straight up.
4. Remove (141) major gasket from the (140) head mani- 13. Remove the (124) O-ring, the (135) vent bushing, and the
fold. (136) U-cup from the (144) valve housing.
5. Remove tubes (114) and (137) by pulling upward. 14. Remove the (128) O-ring and the (126) sleeve from the
6. Remove the four (113) O-rings from both tubes (114) and motor assembly by sliding it straight up.
(137). 15. Pull the (134) spool as far from the motor assembly as
possible to expose the under side of the spool itself.

(continued on page 4)

AF064X-XX and AF066X-XX (en) Page 3 of 8

 DISASSEMBLY OF AIR MOTOR (CONT’D) 13. Slide the (132) driver onto the (120) trip rod assembly.
Align the hole of the (132) driver with the hole in the
16. Locate and remove the (129) snap ring from the (134) (120) trip rod assembly and insert the (131) pin.
spool utilizing snap ring pliers. 14. Assemble the (133) U-cup to the (134) spool. Take note
17. Lift to remove the (134) spool and remove the (133) of the (133) U-cup lips should point down towards the
U-cup. (122) head plate.
18. Slide the (131) pin to remove the (132) driver, (130) 15. Slide the (134) spool onto the (120) trip rod assembly
washer, and (129) snap ring from the (120) trip rod as- over the (132) driver and insert the (130) washer behind
sembly. it. Utilizing snap ring pliers, assemble the (129) snap
19. Remove the four (109) nuts from (121) hex head bolts. ring to the internal groove found in the (134) spool. Be
20. Remove the four (121) bolts from the (122) head plate certain that the (129) snap ring is fully engaged into the
and the (101) base assembly. groove. Slide the (134) spool downward into the bore of
21. Remove (122) head plate from the (112) air cylinder. the (122) head plate nesting on top of the (125) cap.
22. Remove the (111) O-ring, the (125) cap, and (123) O-ring 16. Lubricate the inside diameter of the (126) sleeve and
from the (122) head plate. slide it onto the (134) spool and locating it into the (125)
23. Pull upward on (112) air cylinder until (203) piston as- cap. Take note that large taper on (126) Sleeve is to lo-
sembly separates from the (101) base assembly. If, in this cate into (125) Cap.
step, the (203) piston assembly is not pulled from the 17. Install the (128) O-ring onto the top gland of the (126)
(101) base assembly, then remove it after removing the sleeve.
(112) air cylinder. 18. Install the (136) U-cup, the (135) vent bushing into the
24. If the (112) air cylinder and (203) piston assembly are center bottom bore of the (144) valve housing. Take
removed as one unit, then remove the (203) piston as- note that the (136) U-cup lips must be facing up towards
sembly from the (112) air cylinder. the top of the (144) valve housing. Install the (124)
25. Remove the (116) O-ring from the (117) piston. O-ring into the bottom recess gland of the (144) valve
26. Remove the (111) O-ring from (101) base assembly. housing.
27. For model AF0660-XX, remove (154) snap ring, (153) 19. Install the (144) valve housing to the motor assembly
washer, (152) U-cup, and (151) washer from the (101) by sliding the center bore onto the (134) spool and the
base assembly. For all other models, remove the (102) (126) sleeve. Take caution not to dislodge any of the
O-ring from the (101) base assembly. O-rings (124 & 128). Take note to align the large valve
REASSEMBLY OF AIR MOTOR pocket on the side of the (144) valve housing towards
the notch in the (122) head plate.
1. Apply grease to all O-rings, U-cups, and other rubber 20. Install the two (145) socket head screws thru the (144)
goods before installing. valve housing and thread into the (122) head plate. The
2. For model AF0660-XX, install (151) washer, (152) U-cup, (144) valve housing may need to be rotated slightly to
(153) washer, and (154) snap ring into the (101) base as- align the tapped holes. Tighten the (145) socket head
sembly. For all other models, install the (102) O-ring into screws per specified torque value.
the (101) base assembly. 21. Install the (146) pilot insert, with pocket facing outward,
3. Install the (111) O-ring in the groove on the (101) base thru the (144) valve housing and into the (134) spool.
assembly. The (134) spool may need to be turned to orient its’ shal-
4. Install the (116) O-ring in the groove on the (117) piston. lower slot to face the smaller pocket of the (144) valve
5. Push (115) piston rod thru the (101) base assembly, be- housing.
ing careful not to damage the lips of the (152) U-cup or 22. Install the (147) pilot valve plate, with identification
the (102) O-ring. dimple facing outward, into the (144) valve housing cov-
6. Lubricate the inside diameter of the (112) air cylinder ering the (146) pilot insert.
and slide it down over the (203) piston assembly and 23. Install the (148) pilot gasket into the (150) pilot cover
onto the (101) air motor base assembly. (See Figure 2 on and assemble to the (144) valve block using four (138)
Page 2). socket head screws. Tighten to torque specifications.
7. Align notch in (122) head plate with the port in (101) 24. Install the (143) D-valve, with pocket facing outward,
base assembly and press the (122) head plate down until thru the (144) valve housing and into the (134) spool.
it is seated against the (112) air cylinder. The (120) trip 25. Install the (142) major valve plate, with identification
rod assembly must lead thru the center of the (122) head dimple facing outward, into the (144) valve housing cov-
plate. ering the (143) D-valve.
8. Assemble the four (121) bolts thru the (122) head plate 26. Install the four (113) O-rings onto both (114 & 137) tubes.
and the (101) base assembly. 27. Loosely install the (137) tube into the bore in the (122)
9. Assemble the four (109) nuts to (121) hex head bolts and head plate.
tighten per specified torque sequence and value. 28. Loosely install the (114) tube into the bore in the (101)
10. Pull the (120) trip rod assembly as far out of the air mo- base assembly.
tor assembly as possible, slide the (123) O-ring over the 29. Install the (141) manifold gasket into the (140) man-
(120) trip rod assembly and down into the gland found ifold and telescope onto both (114 & 137) tubes
in the (122) head plate. until the (113) O-rings are seated. Fasten the (140)
11. Slide the (125) cap over the (120) trip rod assembly and manifold to the (144) valve block using four (138) socket
down into the bore found in the (122) head plate. head screws. Tighten to torque specifications.
12. Slide the (129) snap ring first and the (130) washer sec- 30. Install the (155) muffler/(201) muffler assembly.
ondly, onto the (120) trip rod assembly.

Page 4 of 8 AF064X-XX and AF066X-XX (en)

 TROUBLESHOOTING Air leakage out (149) pilot exhaust only during the down
stroke.
Air leakage out of main exhaust. y Worn (133) “U” cup. Rolled or damaged (128) “O” ring. Re-
y Damaged (141) track gasket. Replace (141) track gasket. place (133) “U” cup and (128) “O” ring.
y Worn (116) piston seal. Replace (116) piston seal. Air leakage around (115) piston rod.
Continual air leakage out (149) pilot exhaust. y Worn or damaged (102) “O” ring or (152) “U” cup depend-
y Worn (136) “U” cup. Damaged (148) track gasket. Replace ing on motor model. Replace (102) “O” ring or (152) “U”
(136) “U” cup and (148) track gasket. cup depending on motor model.
VARIETIES OF BASE (101) AND PISTON ROD END (115)

TYPE -5-
TYPE -0- Coupled High Pressure Base,
Divorced Base, Quick Coupled Rod Female Threaded Rod
67462 BASE and 67488 BASE and
67496 PISTON ASSEMBLY 67495 PISTON ASSEMBLY

Air Motor Base and Rod Combination

0 – Divorced pump base with quick coupled rod connection
5 – Coupled high pressure pump base with female threaded rod connection

Figure 4

AF064X-XX and AF066X-XX (en) Page 5 of 8

 Available Options for AF06XX-XX Air Motors

201
Optional
67445-2
202 Muffler Kit
Optional
67442
Self-Relieving
Ball Valve
Regulator / Shut-Off
(AF06XX-01)

Figure 5

Page 6 of 8 AF064X-XX and AF066X-XX (en)

 DIMENSIONAL DATA
Dimensions shown are for reference only, they are displayed in inches.

(1 1/4 - 11 1/2 NPTF-1)

MAJOR EXHAUST PORT

(1/4-18 NPTF-1)
PILOT EXHAUST PORT (7.00) (AF0660-XX)
(6.86) (AF0645-XX)

(3.00)
(1.99)

(2.50)
(3.80)
(7.00)

(1/2-14 NPTF-1)
AIR INLET PORT

(4.06) (2.53)

(4.22) (1.62) (2.25)

(2.75) (2.56)

(2.53) (2.53)

(16.64)

(14.56)

(10.06) (23.27)

(21.18)

(1.17)
(16.68)

(AF0645-XX)

(AF0660-XX)
Figure 6

AF064X-XX and AF066X-XX (en) Page 7 of 8

 PN 97999-1467
Page 8 of 8 AF064X-XX and AF066X-XX (en)