Ingersoll-Rand ARO 66615 Series User manual

INGERSOLL RAND COMPANY INC
209 NORTH MAIN STREET - BRYAN, OHIO 43506
[phone] FAX [phone] © 2023 CCN 81660219
arozone.com
OPERATOR’S MANUAL 66615X-X-C
INCLUDING: OPERATION, INSTALLATION AND MAINTENANCE RELEASED: 5-31-88
REVISED: 3-31-23
(REV: AM)
1-1/2” DIAPHRAGM PUMP
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 ma-
terial options.
637118-C for air section repair (see page 8).
637124-XX for uid section repair (see page 5).
637155 Abrasion Resistant Conversion Kit is available for use
in heavy and abrasive material applications (see page 5).
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 ................. 77.5 lbs (35.15 kgs)
Stainless Steel Flange models .. 88.73 lbs (40.25 kgs)
[add 23 lbs (10.4 kgs) for cast iron air motor section]
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)
Maximum Flow
Rate (ooded inlet) ............. 90 gpm (340.7 lpm)
Displacement / Cycle @ 100 psig
Standard Diaphragm .......... 0.64 gal. (2.42 lit.)
Composite PTFE Diaphgram ... 0.40 gal. (1.52 lit.)
Maximum Particle Size.......... 1/4” dia. (6.4 mm)
Maximum Temperature Limits (diaphragm / ball / seat
material)
Acetal ......................-20º to 180º F (-29º to 82º C)
E.P.R........................ -60º to 280º F (-51º to 138º C)
Hytrel® .....................-20º to 180º F (-29º to 82º C)
PVDF.......................10º to 200º F (-12º to 93º C)
Neoprene ..................0º to 200º F (-18º to 93º C)
Nitrile ......................10º to 180º F (-12º to 82º C)
Polypropylene..............32º to 175º F (0º to 79º C)
Polyurethane...............-10º to 150º F (-23º to 66º C)
PTFE .......................40º to 225º F (4º to 107º C)
Composite PTFE ............14º to 194º F (-10º to 90º C)
Santoprene® ...............-40º to 225º F (-40º to 107º C)
Viton® .....................-40º to 350º F (-40º to 177º C)
Dimensional Data.............See page 10 and 11
Noise Level @
70 psig - 60 cpm.............80.5 dB(A)

Tested with 350-568 muer installed.
The pump sound pressure levels published here have been updated to an Equivalent Contin-
uous Sound Level (LA
eq
) 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 combina-
tions may not be recommended, consult a representative or the factory if you
have questions concerning availability.
66615X-XXX-C
1-1/2”
DIAPHRAGM
PUMP
ALUMINUM / CAST IRON PUMP
STAINLESS STEEL PUMP
STAINLESS STEEL
FLANGE MODEL PUMP
Figure 1

Page 2 of 12 66615X-X-C (en)
MODEL DESCRIPTION CHART
6661 XX
CENTER BODY MATERIAL
5 -
XXXC
-
Aluminum, NPTF
7 - Aluminum, BSP
8 -Cast Iron, BSP
L - Aluminum, FLANGE
FLUID CAP / MANIFOLD MATERIAL
(Steel Hardware)
0 - Aluminum
1 - Stainless Steel
-
2 -Cast Iron
(Stainless Steel Hardware)
A - Aluminum
B - Stainless Steel
C - Cast Iron
BALL MATERIAL
SEAT MATERIAL
1 - Aluminum
2 - 316 Stainless Steel
3 - Polypropylene
4 - PVDF
5 -Carbon Steel
8 - Hard 440 Stainless Steel
E - Stainless Steel, Raised Flange, Center Port
DIAPHRAGM MATERIAL
1 - Neoprene
2 - Nitrile
4 - PTFE
6 - Acetal
8 - Polyurethane
A - Stainless Steel
C - Hytrel
E - Santoprene
2 - Nitrile
3 -Viton®
4 - PTFE / Santoprene
6 -Composite PTFE
9 - Hytrel
B - Santoprene
3 -Viton®
6661XX-X X X C
DIAPHRAGMBALL
FLUID SECTION SERVICE KIT SELECTION
EXAMPLE: MODEL # 666150-361-C
Fluid Section Service Kit # 637124-61
637124 X X - C
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.
6 -Cast Iron, NPTF

66615X-X-C (en) Page 3 of 12
OPERATING AND SAFETY PRECAUTIONS
READ, UNDERSTAND, AND FOLLOW THIS INFORMATION TO AVOID INJURY AND PROPERTY DAMAGE.
EXCESSIVE AIR PRESSURE
STATIC SPARK
HAZARDOUS MATERIALS
HAZARDOUS PRESSURE
WARNING
EXCESSIVE AIR PRESSURE. Can cause per-
sonal injury, pump damage or property damage.
yDo not exceed the maximum inlet air pressure as stat-
ed on the pump model plate.
yBe sure material hoses and other components are
able to withstand fluid pressures developed by this
pump. Check all hoses for damage or wear. Be certain
dispensing device is clean and in proper working con-
dition.
WARNING
STATIC SPARK. Can cause explosion re-
sulting in severe injury or death. Ground pump and
pumping system.
ySparks can ignite ammable material and vapors.
yThe pumping system and object being sprayed must
be grounded when it is pumping, ushing, recirculat-
ing or spraying flammable materials such as paints,
solvents, lacquers, etc. or used in a location where
surrounding atmosphere is conducive to spontaneous
combustion. Ground the dispensing valve or device,
containers, hoses and any object to which material is
being pumped.
yUse the pump grounding screw terminal provided.
Use ARO®part no. 66885-1 ground kit or connect a
suitable ground wire (12 ga. minimum) to a good
earth ground source.
ySecure pump, connections and all contact points to
avoid vibration and generation of contact or static spark.
yConsult local building codes and electrical codes for
specic grounding requirements.
yAftergrounding, periodically verify continuity of elec-
trical path to ground. Test with an ohmmeter from
each component (e.g., hoses, pump, clamps, contain-
er, spray gun, etc.) to ground to ensure continuity.
Ohmmeter should show 0.1 ohms or less.
ySubmerse the outlet hose end, dispensing valve or de-
vice in the material being dispensed if possible. (Avoid
free streaming of material being dispensed.)
yUse hoses incorporating a static wire.
yUse proper ventilation.
yKeep inammables away from heat, open ames and
sparks.
yKeep containers closed when not in use.
WARNING
Pump exhaust may contain contaminants.
Can cause severe injury. Pipe exhaust away from work
area and personnel.
yIn the event of a diaphragm rupture, material can be
forced out of the air exhaust muer.
yPipe the exhaust to a safe remote location when
pumping hazardous or inammable materials.
yUse a grounded 3/4” minimum ID hose between the
pump and the muer.
WARNING
HAZARDOUS PRESSURE. Can result in
serious injury or property damage. Do not service or
clean pump, hoses or dispensing valve while the sys-
tem is pressurized.
yDisconnect air supply line and relieve pressure from
the system by opening dispensing valve or device and
/ or carefully and slowly loosening and removing out-
let hose or piping from pump.
WARNING
HAZARDOUS MATERIALS. Can cause se-
rious injury or property damage. Do not attempt to
return a pump to the factory or service center that
contains hazardous material. Safe handling practices
must comply with local and national laws and safety
code requirements.
yObtain Material Safety Data Sheets on all materials
from the supplier for proper handling instructions.
Obtain Material Safety Data Sheets on all materials
from the supplier for proper handling instructions.
WARNING
EXPLOSION HAZARD. Models containing
aluminum wetted parts cannot be used with 1,1,1-tri-
chloroethane, methylene chloride or other haloge nat-
ed hydrocarbon solvents which may react and explode.
yCheck pump motor section, uid caps, manifolds and
all wetted parts to assure compatibility before using
with solvents of this type.
CAUTION
Verify the chemical compatibility of the
pump wetted parts and the substance being pumped,
flushed or recirculated. Chemical compatibility may
change with temperature and concentration of the
chemical(s) within the substances being pumped,
flushed or circulated. For specific fluid compatibility,
consult the chemical manufacturer.
CAUTION
Maximum temperatures are based on
mechanical stress only. Certain chemicals will signi-
cantly reduce maximum safe operating temperature.
Consult the chemical manufacturer for chemical com-
patibility and temperature limits. Refer to PUMP DATA
on page 1 of this manual.
CAUTION
Be certain all operators of this equipment
have been trained for safe working practices, under-
stand it’s limitations, and wear safety goggles / equip-
ment when required.
CAUTION
Do not use the pump for the structural
support of the piping system. Be certain the system
components are properly supported to prevent stress
on the pump parts.
ySuction and discharge connections should be exible
connections (such as hose), not rigid piped, and should
be compatible with the substance being pumped.
CAUTION
Prevent unnecessary damage to the
pump. Do not allow pump to operate when out of ma-
terial for long periods of time.
yDisconnect air line from pump when system sits idle
for long periods of time.
CAUTION
Use only genuine ARO replacement parts
to assure compatible pressure rating and longest ser-
vice life .
NOTICE
Replacement warning labels are available
upon request: “Static Spark” (93616-1) & “Diaphragm
Rupture” (93122).
WARNING
= Hazards or unsafe practices which
could result in severe personal injury,
death or substantial property damage.
CAUTION
=Hazards or unsafe practices which
could result in minor personal inju-
ry, product or property damage.
NOTICE
=Important installation, operation or
maintenance information.

Page 4 of 12 66615X-X-C (en)
Viton®is a registered trademarks of the Chemours Company Hytrel®is a registered trademark of the DuPont Company ARO®is a registered trademark of Ingersoll Rand Company 
Loctite®,
262™, 271™ and 572™ is a registered trademark of Henkel Corporation Santoprene®is a registered trademark of Celanese Lubriplate® is a registered trademark of Lubriplate Lubricants Company 
GENERAL DESCRIPTION
The ARO diaphragm pump oers 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 / u-
id sections. Air operated double diaphragm pumps utilize a
pressure dierential in the air chambers to alternately create
suction and positive fluid pressure in the fluid chambers,
valve checks ensure a positive ow of uid. 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.
AIR AND LUBE REQUIREMENTS
EXCESSIVE AIR PRESSURE. Can cause personal injury, pump
damage or property damage.
yA filter capable of filtering out particles larger than 50
microns should be used on the air supply. There is no lu-
brication required other than the “O” ring lubricant which
is applied during assembly or repair.
yIf 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
yAlways flush the pump with a solvent compatible with
the material being pumped if the material being pumped
is subject to “setting up” when not in use for a period of
time.
yDisconnect the air supply from the pump if it is to be in-
active for a few hours.
yThe outlet material volume is governed not only by the air
supply, but also by the material supply available at the in-
let. The material supply tubing should not be too small or
restrictive. Be sure not to use hose which might co lapse.
yWhen the diaphragm pump is used in a forced-feed
(ooded inlet) situation, it is recommended that a “Check
Valve”be installed at the air inlet.
ySecure the diaphragm pump legs to a suitable surface to
ensure against damage by vibration.
MAINTENANCE
Refer to the part views and descriptions as provided on pag-
es 5 through 9 for parts identication and service kit informa-
tion.
yCertain ARO “Smart Parts” are indicated which should be
available for fast repair and reduction of down time.
yService 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.
yProvide a clean work surface to protect sensitive internal
moving parts from contamination from dirt and foreign
matter during service disassembly and reassembly.
yKeep good records of service activity and include pump
in preventive maintenance program.
yBefore disassembling, empty captured material in the
outlet manifold by turning the pump upside down to
drain material from the pump.
FLUID SECTION DISASSEMBLY
1. Remove top manifold(s).
2. Remove (22) balls, (19) “O”rings and (21) seats.
3. Remove (15) uid caps.
NOTE: Only PTFE diaphragm models use a primary dia-
phragm (7) and a backup diaphragm (8). Refer to the auxiliary
view in the Fluid Section illustration.
For 6661XX-XX6-C:
4. Remove (7)diaphragm, (5)washers and (30)shims.
For other models:
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
yReassemble in reverse order.
yClean and inspect all parts. Replace worn or damaged
parts with new parts as required.
yLubricate (1) diaphragm rod and (2) “O” ring with Lubri-
plate® FML-2
yInstall (2) “O” ring on (1) diaphragm rod.
For 6661XX-XX6-C:
yAttach a regulated airline to the pump inlet; gradually
increasing the air pressure (6-8 psi) to check which side of
the pump with air blowing out, and then shut down the
air supplier.
yFasten (7) diaphragm with (5) washer into (1) diaphragm
rod, and insert them into (101) Center body from the
chamber identied with blowing air in the previous step.
yInstall (15) uid cap.
yThread the other side of (7) diaphragm with (5) washer
into (1) diaphragm rod, but do not tighten it.
yRecord the angle for the misalignment between (7) dia-
phragm hole and (101) center body holes, then unthread
the (7) diaphragm and place proper Qty. of (30) shims be-
tween (5) washer and (1) diaphragm rod.
yAttach a regulated airline to the pump inlet, gradually
increasing the air pressure (6-8 psi) until the diaphragm
shift to the other site, shut down the air supply.
yInstall the second (15) uid cap.
NOTE: For details, refer to service kits manual 48495949.
For other models:
yBe certain (7) or (7 / 8) diaphragm(s) align properly with
(15) uid caps before making nal torque adjustments on
bolt and nuts to avoid twisting the diaphragm.
yFor 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
uid cap.
yCheck all torque settings after pump has been re-started
and run a while.

66615X-X-C (en) Page 5 of 12
637155
ABRASION RESISTANT
CONVERSION KIT
Includes:
93266 (4) [SH] Seat
92757-8 (4) [U] Ball
MATERIAL CODE
[A] = Aluminum
[B] = Nitrile
[C] = Carbon Steel
[CI] = Cast Iron
[Co]= Copper
[CP] = Composite PTFE
[D] = Acetal
[E] = E.P.R.
[H] = Hytrel
[K] = PVDF
[N] = Neoprene
[P] = Polypropylene
[SH] = Hard Stainless Steel
[Sp] = Santoprene
[SS] = Stainless Steel
[T] = PTFE
[U] = Polyurethane
[V] = Viton
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), 94276 Lubriplate® FML-2 packet, plus items: 2, 3, 9 and 19.
SEAT OPTIONS
6661XX-XXX-C BALL OPTIONS 6661XX-XXX-C
“21”

“22” (1-1/4” dia.)
-XXX Seat Qty [Mtl] -XXX Ball Qty [Mtl] -XXX Ball Qty [Mtl]
-1XX 92760 (4) [A] -X2X 92757-2 (4) [B] -XAX 94804 (4) [SS]
-2XX 92776 (4) [SS] -X3X 92757-3 (4) [V] -XCX 92757-C (4) [H]
-3XX 92924 (4) [P] -X4X 92757-4 (4) [T] -XEX 92757-A (4) [Sp]
-4XX 94514 (4) [K] -X6X 92757-6 (4) [D]
-5XX 95676 (4) [C] -X8X 92757-8 (4) [U]
-8XX 93266 (4) [SH]
DIAPHRAGM OPTIONS 6661XX-XXX-C

SERVICE KIT

“7”

“8”

“3” (1/16” x 3/4” OD)

“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] --- --- --- Y325-16 (4) [B] Y325-230 (4) [B]
-XX2 637124-X2 92755-2 (2) [B] --- --- --- Y325-16 (4) [B] Y325-230 (4) [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]
-XX6 48496806 48490064 (2) [CP] --- --- --- --- --- --- Y220-230 (4) [T]
-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 6661XX-XXX-C
Aluminum
6661X0-X, 6661XA-X
Stainless Steel
6661X1-X, 6661XB-X,6661LE-X
Cast Iron
6661X2-X, 6661XC-X
NPTF BSP NPTF BSP Flange
Model NPTF BSP
Item Description (Size) Qty Part No. Part No. [Mtl] Part No. Part No. Part No. [Mtl] Part No. Part No. [Mtl]
15 Fluid Cap (2) 92750 92750 [A] 97621 97621 97621 [SS] 92778 92778 [CI]
16 Manifold (6661X0, 1X2, 1XA,1XC) (2) 92749 92749-1 [A] - - - - - - - - - - - - - - - - - - 92777 92777-1 [CI]
60 Inlet Manifold
(6661X1, 1XB, 1LE) (1) - - - - - - - - - - - - - 97624 97624-1 98341 [SS] - - - - - - - - - - - - -
61 Outlet Manifold
(6661X1, 1XB, 1LE) (1) - - - - - - - - - - - - - 97623 97623-1 98342 [SS] - - - - - - - - - - - - -
HARDWARE OPTIONS 6661XX-XXX-C
Item Description (Size) Qty
Carbon Steel
6661X0-, 1-, 2-
Stainless Steel
6661XA-, B-, C-, E-
Part No. [Mtl] Part No. [Mtl]
26 Bolt (3/8” - 16 x 1-1/4”) (8) Y6-66-C [C] Y6-66-T [SS]
27 Bolt (5/16” - 18 x 2-1/4”) (6661X0, 1X2, 1XA, 1XC) (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 (6661X0, 1X2, 1XA,1XC) (2) 92759 [C] 92759-1 [SS]
◆
59
Bolt (5/16” - 18 x 2”) (6661X0-XX6-C) (16) 47512837001 [C] 47510437001 [SS]
(6661XB-XX6-C, 6661LE-XX6-C) (20) 47512837001 [C] 47510437001 [SS]
(6661X0, 1X2, 1XA, 1XC) (16) 93608 [C] Y6-59-T [SS]
(6661X1, 1XB, 1LE) (20) 93608 [C] Y6-59-T [SS]
COMMON PARTS
Item Description (size in inches) Qty Part No. [Mtl]
1 Rod (6661XX-XX6-C) (1) 48489819 [C]
(other models) (1) 98720-1 [C]
2 ‘‘O” Ring (3/32” x 1” OD) (1) Y330-117 [B]
5 Plate (air side) (6661XX-XX6-C) (2) 48496673 [C]
(Other models) (2) 92752 [C]
6 Plate (uid side)(2) 92775 [SS]
(models 6661X0 only) (2) 92752 [C]
COMMON PARTS
Item Description (size in inches) Qty Part No. [Mtl]
9 Washer (0.630” ID)(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]
30 Shim (6661XX-XX6-C) () 48499875 # [C]

The quantity is between 0 to 5, shims are not shown in the exploded view.

“Smart Parts” keep these items on hand in addition to the Service Kits for fast repair and reduction of down time.
# For service, shim pack 48499339 can be purchased. Refer to service kits manual 48495949 for details.
For 6661XX-XX6-C, on the uid side, washer (6), (9) and screw (14) are not needed.
◆
For 6661X1, 1XB legs (32) and Bolt (27) are not needed, Bolt(59) required in 20 quantity.

Page 6 of 12 66615X-X-C (en)
PARTS LIST / 6661X0, 1X2, 1XA and 1XC FLUID SECTION
1
29
Tab
73
21
19 
22
26
16
59
15
22
21
19
16
27
32
14
9
6
5
2 
Tab
7PTFE
(white)
Santoprene 8
(Green when used as backer)
Air
Side
Fluid
Side
Fluid
Side
Air
Side
CrossSectionViewofDiaphragms
5
7
2
3
4
1
8
6
Torque Sequence
901
3 
26











NOTE: DO NOT OVERTIGHTENFASTENERS.
(14) Diaphragm screw,65-70 ft lbs (88.1 - 94.9Nm.).
(26) Bolts, 240 - 280 in.lbs (27.1 - 31.6 Nm).
(29) Nuts, 120 - 140 in.lbs (13.6-15.8 Nm).
kApply Lubriplate® FML-2 to all “O” rings,
“U” Cups and mating parts.
zApply Loctite271 to threads
UApply anti-seize compound to threads and bolt and nut
ange heads which contact pump case when using
stainless steel fasteners.
COLOR CODE
See item 8ininset below.
Acetal
E.P.R.
Hytrel
Neoprene
Nitrile
Santoprene
PTFE
Polyurethane
Viton
N/A
Blue(-)
Cream
Green(-)
Black
Tan
White
N/A
Yellow(-)
(-)Stripe
Orange
Blue(•)
Cream
Green(•)
Red(•)
Tan
White
Red
Yellow(•)
(•)Dot
Material
Diaphragm
color
Ball
Color
TORQUE REQUIREMENTS
LUBRICATION/ SEALANTS
FOR THE
AIR MOTOR SECTION
SEE PAGES 8 AND 9
View for 6661XX-XX4-C (PTFE diaphragm) conguration only.
Figure 2

66615X-X-C (en) Page 7 of 12
PARTS LIST / 6661X1, 1XB and 1LE FLUID SECTION
1
29 ,U
.,
NOTE: DO NOT OVERTIGHTENFASTENERS.
(14) Diaphragm screw, 65 -70ft lbs (88.1 - 94.9 Nm.).
(26)Bolts, 240 - 280 in. lbs (27.1 - 31.6Nm).
(29) Nuts, 120-140 in. lbs(13.6 - 15.8 Nm).
kApply Lubriplate® FML-2 to all “O” rings,
“U” Cups & mating parts.
zApply Loctite271tothreads
UApply anti-seize compound to threads and bolt and nut
ange heads which contact pump case when using
stainless steel fasteners.
7
k
3
COLORCODE
Seeitem 8ininset below.
26 ,U
61
61 (6661LE)
59
U
15
22
21
19k
60
60 (6661LE)
27U
14,z
9
6
5
2k
Air Side
Fluid Side
Fluid Side
Air Side
Cross Section View of Diaphragms
5
7
2
3
4
1
8
6
Torque Sequence
901
View for 6661XX-XX4 -C (PTFE diaphragm) conguration only.
Tab
7PTFE
(white)
Santoprene 8
(Green when used as backer)
3k
26,U
Acetal
E.P.R.
Hytrel
Neoprene
Nitrile
Santoprene
PTFE
Polyurethane
Viton
N/A
Blue(-)
Cream
Green(-)
Black
Tan
White
N/A
Yellow(-)
(-)Stripe
Orange
Blue(•)
Cream
Green(•)
Red(•)
Tan
White
Red
Yellow(•)
(•)Dot
Material
Diaphragm
color
Ball
Color
LUBRICATION/SEALANTS
TORQUE REQUIREMENTS
22
21
19k
Tab
FOR THE
AIR MOTOR SECTION
SEE PAGES 8 AND 9
Figure 3

Page 8 of 12 66615X-X-C (en)
“Smart Parts” Keep these items on hand in addition to the Service Kits for fast repair and reduction of down time.
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]
101
Motor Body
(66615X-X, 66617X-X, 6661LX-X) (1) 94744 [A]
(66616X-X, 66618X-X) (1) 94742 [CI]

102 ‘‘O” Ring (1/16” x 1-1/4” OD) (2) Y325-24 [B]
103 Sleeve (1) 94528 [D]

104 Retaining Ring, TruArc (1-5/32” ID) (2) Y145-26 [C]
105
Screw / Lockwasher (1/4”- 20 x 5/8”)
(models 6661X0-X, 6661X1-X, 6661X2-X) (8) 93860 [C]
(6661XA-X, 6661XB-X, 6661XC-X, 6661LX-X) (8) Y6-42-T [SS]
106 Lockwasher (1/4”) (models 6661XA-X,
6661XB-X, 6661XC-X, 6661LX-X only) (8) Y14-416-T [SS]
107 Plate (2) 93707-1 [SS]

108 Gasket (with notch) (1) 92878 [B/Ny]
109 Piston (1) 92011 [D]

110 “U” Cup (3/16” x 1-3/8” OD) (1) Y186-51 [B]
111
Spool
(models 66615X-X, 66617X-X, 6661LE-X) (1) 92005 [A]
(models 66616X-X, 66618X-X) (1) 93047 [C]
112 Washer (1.557” OD) (5) 92877 [Z]

113 “O” Ring (small) (1/8” x 1-1/4” OD) (5) Y325-214 [B]
Item Description (size) Qty Part No. [Mtl]

114 “O” Ring (large) (3/32” x 1-9/16” OD) (6) Y325-126 [B]
115 Spacer (4) 92876 [Z]
116 Spacer (1) 92006 [Z]

117 Gasket (1) 92004 [B/Ny]
118 Pilot Rod (1) 93309-2 [C]

119 “O” Ring (1/8” x 3/4” OD) (4) 93075 [U]
120 Spacer (3) 115959 [Z]
121 Sleeve Bushing (2) 98723-2 [Bz]
122
“O” Ring (3/32” x 9/16” OD) (2) 94820 [U]

123 Screw (#8 - 32 x 3/8”) (4) Y154-41 [C]
126 Pipe Plug (1/2 - 14 PTF x 17/32”) (1) Y227-5-L [C]
127 90º Street Elbow (3/4 - 14 NPTF) (1) Y43-5-C [C]
128 Pipe Plug (1/8 - 27 PTF x 1/4”) (1) Y227-2-L [C]
195A Button Head Screw (1/4”- 20 x 1/4”) (2) 94987 [SS]
195B Button Head Screw (1/4”- 20 x 3/8”) (1) 94987-1 [SS]
201 Muer (1) 350-568
231 Pipe Plug (1/4 - 18 NPTF x 0.41”)
(models 66616X-X and 66618X-X only) (2) Y17-51-S [SS]

Lubriplate® FML-2 (1) 94276
Lubriplate® Grease Packets (10) 637308
AIR MOTOR SECTION SERVICE
Service is divided into two parts - 1. Pilot Valve, 2. Major
Valve.
GENERAL REASSEMBLY NOTES:
yAir Motor Section Service is continued from Fluid Section
repair.
yInspect and replace old parts with new parts as
necessary. Look for deep scratches on metallic surfaces,
and nicks or cuts in “O” rings.
yTake precautions to prevent cutting “O” rings upon
installation.
yLubricate“O” rings with Lubriplate® FML-2.
yDo not over-tighten fasteners, refer to torque specifica-
tion block on view.
yMake sure to torque all fasteners following restart.
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 rein-
stall (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 re-
tain on each end with the two (122) “O” rings, retain with
(123) screws.
4. Replace (104) retaining rings.
MATERIAL CODE
[A] = Aluminum [CI] = Cast Iron [SS] = Stainless Steel
[B] = Nitrile [D] = Acetal [U]= Polyurethane
[Bz] = Bronze [Ny] = Nylon [Z] = Zinc
[C] = Carbon Steel
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 di-
ameter 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 (107).

66615X-X-C (en) Page 9 of 12
PARTS LIST / 66615X-X-C AIR SECTION
MAJOR VALVE
PILOT VALVE
118
111
112
113
114
116115
117
119
122
102

104
123
121
120
108
109
110
106
105

NOTE: DO NOT OVERTIGHTENFASTENERS.
(105)40-50 in.lbs (4.5 - 5.6 Nm).
(123) Screw, 20 -25 in. lbs (2.3 - 2.8 Nm).
LUBRICATION / SEALANTS
Apply Lubriplate® FML-2 to all“O” rings,“U” Cups &matingparts.
Apply Loctite 262 to threads.
Apply Loctite 271 to threads.

Apply Loctite 572 to threads.
Seecross section detail, gure5.
128
MAJORVALVE CROSS SECTION DETAIL
109 110112 114113 115 111 116
107
126
BE CERTAINTOORIENT(115) SPACER LEGS
AWAY FROM BLOCKING INTERNAL PORTS
WHEN REASSEMBLING AIR SECTION.
195A
195B
101
231
104
103

107
106
105
123
121
195A
43
201
127




TORQUE REQUIREMENTS
IMPORTANT
Figure 5
Figure 4

Page 10 of 12 66615X-X-C (en)
TROUBLESHOOTING
Product discharged from exhaust outlet.
yCheck for diaphragm rupture.
yCheck tightness of (14) diaphragm screw.
Air bubbles in product discharge.
yCheck connections of suction plumbing.
yCheck “O” rings between intake manifold and uid caps.
yCheck tightness of (14) diaphragm screw.
Low output volume, erratic ow, or no ow.
yCheck air supply.
yCheck for plugged outlet hose.
yCheck for kinked (restrictive) outlet material hose.
yCheck for kinked (restrictive) or collapsed inlet material
hose.
yCheck for pump cavitation - suction pipe should be sized
at least as large as the inlet thread diameter of the pump
for proper ow if high viscosity uids are being pumped.
Suction hose must be a non-collapsing type, capable of
pulling a high vacuum.
yCheck all joints on the inlet manifolds and suction con-
nections. These must be air tight.
yInspect the pump for solid objects lodged in the dia-
phragm chamber or the seat area.
DIMENSIONAL DATA - 6661X0, 1X2, 1XA and 1XC
Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
Air Inlet
1/2 - 14 NPTF - 1
Material Outlet
1-1/2 - 11-1/2 NPTF - 1 (66615X, 66616X)
1-1/2 - 11 BSP (66617X, 66618X)
Air Exhaust
3/4 - 14 NPTF - 1
Material Inlet
1-1/2 - 11-1/2 NPTF - 1
(66615X-X-C, 66616X-X-C)
1-1/2 - 11 BSP
(66617X-X-C, 66618X-X-C)
13.12" (333 mm)
18.37"
(467 mm)
7.62"
(194 mm)
2.75"
(70 mm)
12" (305 mm)
10.75" (273 mm)
19.62"
(498 mm)
.50" (14 mm) 9" (229 mm)
11.50" (292 mm)
14.81" (376 mm)
Figure 6

66615X-X-C (en) Page 11 of 12
DIMENSIONAL DATA - 6661X1 and 1XB
Air Inlet
1/2-14 NPTF-1
Material Outlet
1-1/2 - 11-1/2 NPTF (66615X, 66616X)
1-1/2 - 11 BSP (66617X, 66618X)
Air Exhaust Thread
3/4-14 NPTF-1
Material Inlet
1- 11-1/2 NPTF (66615X, 66616X)
1- 11 BSP (66617X, 66618X)
2.75" (70 mm)
10.75" (273 mm)
12" (305 mm)
13.31" (337 mm)
18.37"
(467 mm)
7.62"
(194 mm)
9" (229 mm) .53"
(13.5 mm
)
19.62"
(498 mm)
14.50" (368 mm)
11.25” (286 mm)
11.50" (292 mm)
Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
Figure 7
DIMENSIONAL DATA - 6661LE
Ø 3.37”
(86 mm)
8.23”
(209 mm)
6.64” (169 mm)
13.28” (337 mm)
14.49” (368 mm)
Ø 11.50
(292 mm) 21.94”
(557 mm)
3.23”
(82 mm)
11.25”
(286 mm)
20.11”
(511 mm)
3.18”
(81 mm)
Air Inlet
1/2-14 NPTF-1
Material Inlet
1.5" Hybrid ANSI / DIN / JIS RF Flange
Ø 4.33” (110 mm)
(R.375) TYP
18.98”
(482 mm)
Ø 3.88” (99 mm)
Material Outlet
1.5" Hybrid ANSI / DIN / JIS RF Flange
0.75” (19 mm)
4 PLACES
Dimensions shown are for reference only, they are displayed in inches and millimeters (mm).
Figure 8

Page 12 of 12 66615X-X-C (en)
PN 97999-96