Ingersol Rand G2E Setup guide

04581245
Edition 2
May 2014
Save These Instructions
Air Grinder,
Die Grinder and Sander
Series G2 (Angle)
Maintenance Information

2 04581245_ed2
Product Safety Information
WARNING
Failure to observe the following warnings, and to avoid these potentially hazardous situations, could result in death or serious injury.
Read and understand this and all other supplied manuals before installing, operating, repairing, maintaining, changing accessories on, or
working near this product.
Always wear eye protection when operating or performing maintenance on this tool. The grade of protection required should be assessed
for each use and may include impact-resistant glasses with side shields, goggles, or a full face shield over those glasses.
Always turn o the air supply, bleed the air pressure and disconnect the air supply hose when not in use, before installing, removing or
adjusting any accessory on this tool, or before performing any maintenance on this tool or any accessory.
Do not use this tool if the actual free speed exceeds the rated rpm. Check the free speed of this tool before mounting any accessories, after
all tool repairs, before each job and after every 8 hours of use. Check speed with a calibrated tachometer, without the abrasive product
installed.
Note: When reading the instructions, refer to exploded diagrams in parts Information Manuals when applicable (see under Related Documentation
for form numbers).
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Whenever one of these Grinder, Die Grinder or Sander is
disassembled for overhaul or replacement of parts, lubricate the tool
as follows:
Always wipe the Vanes (28) with a light lm of oil before inserting
them into the vane slots.
Inject 0.5 to 1.0 cm3 of Ingersoll Rand No. 10 Oil into the air Inlet
Assembly (1) after assembly.
1.
2.
Whenever a new Wick (53 or 72) is installed, soak the Wick in
approximately 1-1/2 cm³ of Ingersoll Rand No. 63 Oil. Do not
substitute any other oil.
Whenever the motor is disassembled, remove the old grease and
rell the cavity behind the Rear Rotor Bearing (25) with 3/4 cm³ of
Ingersoll Rand No. 68 Grease.
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4.
General Instructions
Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
When grasping a tool or part in a vise, always use softsided vise
jaws to protect the surface of the part or tool and help prevent
distortion. This is particularly true of threaded members and
housings.
When grasping a tool in a vise, rst place the tool housing in the
provided Clamp Tool (38), then grasp outer surface of Clamp Tool
in the vise to protect the housing from damage.
Do not remove any part which is a press t in or on a subassembly
unless the removal of that part is necessary for repairs or
replacement.
Do not disassemble the tool unless you have a complete set of
new gaskets and O-Rings for replacement.
Do not press any needle bearing from a part unless you have a
new needle bearing on hand for installation. Needle bearings are
always damaged during the removal process.
Disassembly of all Angle Heads
For all Collet models, grasp the tool, mounted in the Clamp Tool
(96), in soft-sided vise jaws with the Collet (77) upward. Using the
Collet Body Wrench (89) on the ats of the Collet Arbor (76) and
the Collet Nut Wrench (90) on the Collet Nut (78), unscrew the
Collet Nut and remove the Collet.
For All Wheel models grasp the tool, mounted in the Clamp Tool
(96), in soft-sided vise jaws with the Flange Nut (85) upward.
For models ending in P945, P95 or P96 use a 4 mm hex wrench
to unscrew the Wheel Retaining Screw (87).
Use the Arbor Wrench (91) to hold the Arbor (76) and using the
Flange Nut Wrench (93 or 94), unscrew and remove the Flange
Nut. Remove the Wheel Retaining Screw Washer (88), the wheel,
Wheel Flange (84) and Flange spacer (86) from the Arbor.
For G2E models, using a 9/64”hex wrench, loosen the Wheel
Guard Adapter Screw (80) and remove the Guard Adapter
Assembly (79) from the Angle Housing Assembly (48).
For G2A and G2L models, using a 5/32”hex wrench, loosen
Guard Adapter Screw (80) and remove the Guard Adapter
Assembly (79) from the Angle Housing Assembly (67).
6. Using a 1/8”hex wrench, unscrew and remove the three Guard
Mounting Screws (83), Guard Lock Washers (82) and Wheel Guard
(81).
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7. For all Sander models, grasp the tool, mounted in the Clamp Tool
(96), in soft-sided vise jaws with the Arbor (76) facing upward.
For All models - Continue Here
8. For G2A and G2L models, using a spanner wrench, unscrew and
remove the Arbor Bearing Cap (75). This is a left-hand thread.
Rotate the Cap Wrench clockwise to remove the Cap.
For G2E models, using the Arbor Bearing Cap Wrench (92),
unscrew and remove the Arbor Bearing Cap (56). This is a left-
hand thread. Rotate the Cap Wrench clockwise to remove the
Cap.
9. For G2A and G2L models, using the Clamp Nut Wrench (95),
loosen the Clamp Nut (69) and pull the Angle Housing Assembly
(67) away from the Motor Housing (12) or Extension Housing (61).
This is a left-hand thread. Rotate the Nut Wrench clockwise to
loosen the Nut.
For G2E models, using the Clamp Nut Wrench (95), loosen the
Clamp Nut (50) and pull the Angle Housing Assembly (48) away
from the Extension Housing (43). This is a left-hand thread. Rotate
the Nut Wrench clockwise to loosen the Nut.
10. Grasp the Arbor and pull the assembled Arbor out of the Angle
Head. If the Wick (53 or 72) needs replacement, pull it out of the
Angle Housing.
11. If the Upper Arbor Bearing (52 or 71) needs replacement, support
the Angle Head on the table of an arbor press, bearing end down,
and press the Bearing out of the Angle Head.
12. Grasp the Arbor in soft sided vise jaws with the output end
downward. Using an adjustable wrench, unscrew and remove the
Bevel Gear Nut (54 or 73) and lift the Bevel Gear (66) o the Arbor.
13. If the Lower Arbor Bearing (55 or 74) must be replaced, use a
piece of tubing to support the Bearing on the table of an arbor
press and press the Arbor from the Bearing.
WARNING
When removing the Clamp Nut in the following procedure, take
all precautions necessary to prevent the Spacer from being
forcefully ejected in a manner or direction that is hazardous.
14. If the Clamp Nut (50 or 69) must be removed from the Angle
Housing, insert the blades of two screwdrivers, approximately
180 degrees apart, under the Clamp Spacer (49 or 68) and pry the
Spacer o the Housing.
Lubrication
Disassembly

04581245_ed2 3
Disassembly of Extension Assembly on G2E and G2L
Models
Grasp the tool mounted in the Clamp Tool (96), in softsided vise
jaws with the Spindle (64 or 45) upward. Using the Clamp nut
Wrench (95) on the ats of the Extension Housing (43 or 61),
unscrew and remove the assembled Housing. This is a left-hand
thread. Rotate the Housing clockwise to remove it. Remove the
Arbor Coupling (39 or 57) and Clamp Sleeve (40 or 58).
For G2E models, using snap ring pliers, remove the Coupling
Retaining Ring (42) from the Spindle Bearing Nut (41) in the large
end of the Extension Housing.
After removing the Retaining Ring, push on the Nut end of the
Spindle until the assembled Spindle exits the angle head end of
the Extension Housing. The Rear Spindle Bearing (44) will remain
in the Housing and the Nut will pass through the Bearing.
If the Front Spindle Bearing (46) must be replaced, use a 1/2”
wrench on the ats of the Bevel Pinion (47) and the Spindle
Bearing Nut to unscrew and remove either the Pinion or Nut.
Using an adjustable wrench on the ats of the Spindle, remove
whichever component remained threaded onto the Spindle. Press
the Bearing from the Spindle.
If the Rear Spindle Bearing must be replaced, press the Bearing
out of the large end of the Extension Housing.
For G2L models, grasp the Bevel Pinion (66) and pull the
assembled Spindle from the Extension Housing. Remove the two
Rear Spindle Bearing Washers (63) from the Housing.
Using snap ring pliers, remove the Coupling Retaining Ring (60)
from the Spindle Bearing Nut (59) on the assembled Spindle.
Grasp a 5/32”diameter steel pin vertically in a set of vise jaws and
slide the crosshole of the assembled Spindle down onto the pin.
Using a 1/2”wrench, unscrew and remove the Spindle Bearing
Nut.
Using a 9/16”wrench, unscrew and remove the Bevel Pinion.
Using a bearing puller, pull the Rear Spindle Bearing (62) o the
Spindle.
Using a bearing puller or arbor press, pull or press the Front
Spindle Bearing (65) o the Spindle.
Disassembly of the Motor
Remove the Flange clamp (35) and front Housing Cap (34) from
the front of the Motor Housing Assembly (12). Remove the Front
Muer (33) if it remains in the Housing.
Grasp the Bevel Pinion (66) or Spindle Bearing Nut (41 or 59) and
pull the assembled motor out of the Motor Housing. Remove
the two Rear Rotor Bearing Spacers (26) from the bottom of the
Cylinder (17).
Remove the Vanes (28) from the Rotor (27).
Grasp the Rotor in smooth sided vise jaws with the Bevel Pinion
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or Spindle Bearing Nut upward. Using a 1/2”wrench for the Nut
or a 9/16”wrench for the Pinion, unscrew and remove the Pinion
or Nut.
If the Front Rotor Bearing (32) must be replaced, support the
Front End Plate (29) between two blocks on the table of an
arbor press. Place the blocks as close to the body of the Rotor
as possible and press the Rotor from the Bearing and End Plate.
Remove the Front End Plate Spacer (30) and Seal Assembly (31)
from the hub of the Rotor.
If the Rear Rotor Bearing (25) must be replaced, use snap ring
pliers to remove the Rear Rotor Bearing Retainer (24).
Using a bearing puller, pull the Rear Rotor Bearing o the hub of
the Rotor.
Disassembly of the Inlet and Throttle
Using a 15/16”wrench or six point socket, unscrew and remove
the Inlet Assembly (1).
Remove the Inlet Seal (2), Inlet Screen and Ball Valve Spring Seat
from the Inlet.
Remove the Ball (4) and Ball Valve Spring (3) from the Cylinder
Assembly (17).
Press the Throttle Lever Pin (7) from the Rear Exhaust Diuser (5)
and remove the Lever Assembly (9).
Remove the Rear Exhaust Diuser from the Housing. Remove Rear
Exhaust Diuser Gasket (8), Rear Exhaust Diuser Muer (10) and
Lever Support (6) from the Diuser.
If the Ball Valve Seat (16) must be replaced, insert a hooked
tool through the central opening of the Seat and, catching the
underside of the Seat, pull it from the Housing.
Remove Rear Housing Muer (11) from the Housing.
Push throttle Pin Assembly (18) out of Housing and remove from
opening in Cylinder.
Remove Throttle Pin O-Ring (19) from throttle Pin.
Disassembly of Motor Housing and Cylinder
Place Cylinder, Inlet end down, on at hard surface. Grasp
Housing and pull down to separate it from the Cylinder. Pull
Cylinder out of Housing.
Remove Flow Guide Assembly (20) and Intake Cover Assembly
(22) from Exhaust Seal (14).
Remove Flow Guide O-Rings (21) from Flow Guide.
Remove Intake Cover O-Ring (23) from Intake Cover.
Remove Rear Cylinder O-Ring (13) and then the Exhaust Seal from
the Cylinder.
Remove Front Cylinder O-Ring (15) from the Cylinder.
If the Throttle Bushing needs to be replaced, insert a small hooked
tool into the hole in the bushing and catch the underside. Pull
Bushing from Cylinder.
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Assembly
General Instructions
Always press on the inner ring of a ball-type bearing when
installing the bearing on a shaft.
Always press on the outer ring of a ball-type bearing when
pressing the bearing into a bearing recess.
Whenever grasping a tool or part in a vise, always use soft-sided
vise jaws. Take extra care not to damage threads or distort
housings.
When grasping a tool in a vise, rst place the tool housing in the
provided Clamp Tool (38), then grasp outer surface of Clamp Tool
in the vise to protect the housing from damage.
Except for bearings, always clean every part and wipe every part
with a thin lm of oil before installation.
Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in clean solvent and dry with a clean
cloth. Sealed or shielded bearings should not be cleaned. Work
grease into every open bearing before installation.
Apply a lm of O-Ring lubricant to every O-Ring before
installation.
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Unless otherwise noted, always press on the stamped end of a
needle bearing when installing a needle bearing into a recess.
Assembly of Motor Housing and Cylinder
If the Throttle Bushing was removed, Properly secure the Cylinder
(17) and press the Throttle Bushing into the hole on the side of
the Cylinder closest to threaded opening.
Apply O-Ring lubricant to the Front Cylinder O-Ring (15) and
install onto the small end of Cylinder. Slide O-Ring past all inlet
and exhaust slots, into Front O-Ring groove.
Install Exhaust Seal (14) onto small end of Cylinder and move it
all the way down over O-Ring. Line up and seat protrusion on
Exhaust Seal with slot in Cylinder for proper orientation.
Install the Rear Cylinder O-Ring (13) onto small end of Cylinder.
Slide O-Ring into rear O-Ring groove in Cylinder.
Install two Flow Guide O-Rings (21) in grooves on Flow Guide (20).
Install Intake Cover O-Ring (23) in groove on Intake Cover (22).
Assemble Flow Guide onto Cylinder. Be sure O-Rings are installed
on the Flow Guide before assembly. For rear exhaust insert the
rubber plugs on the Flow Guide into the holes in the Exhaust Seal.
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4 04581245_ed2
For front exhaust, insert the Flow Guide tabs into the Exhaust Seal
holes. There is a protrusion on the Exhaust Seal that inserts into
the groove in the top of the Flow Guide. Especially, for Flow Guide
without tabs, be sure this protrusion is inserted in this groove.
Assemble Intake Cover onto Cylinder. There is a tab on the front of
the Intake Cover that inserts into the Exhaust Seal and a tab that
inserts into a hole in the Cylinder for proper alignment.
Place large end of Cylinder on at hard surface and slide Housing
(12) over Cylinder assembly. Be sure that hole in top of Housing
lines up with hole in Throttle Bushing. Press down on Housing
until these holes are aligned.
Assembly of the Throttle and Inlet
If the Ball Valve Seat (16) was removed, use a 5/8”wooden dowel
with a at end to push the Seat into the Cylinder.
Assemble Throttle Pin O-Ring (19) onto Throttle Pin (18).
Using needle nose pliers, grasp Throttle Pin above O-Ring and
insert into threaded end of Cylinder. Align Pin with holes in
Cylinder and Housing and insert. Release Throttle Pin and push it
the rest of the way into the hole.
Insert the Ball (4) and then the Ball Valve Spring (3) small end rst
into the Cylinder opening.
Assemble Lever Support (6) into Rear Exhaust Diuser (5), the
U shaped side of support inserted rst into front of the Diuser.
Slide tabs into the slots on the Diuser and line up the holes with
the holes in the Diuser.
Assemble Rear Exhaust Diuser Gasket (8) onto Rear Exhaust
Diuser and assemble Diuser onto the Housing Assembly.
Align hole in Lever Assembly (9) with hole in Exhaust Diuser and
press the Throttle Lever Pin (7) through Exhaust Diuser holes.
Push the Inlet Screen closed end leading, into the small end of the
Inlet Assembly (1). After lubricating the Inlet Seal (2) with O-Ring
lubricant and being careful not to nick the Seal on the threads of
the Inlet, install the Seal on the Inlet. Press the Ball Valve Spring
Seat small end leading into the small end of the Inlet.
Thread the Inlet Assembly into the Cylinder and tighten it
between 20 to 25 ft–lb (27.1 to 33.9 Nm) torque.
Assembly of the Motor
If the Rear Rotor Bearing (25) was removed, stand the Rotor (27)
upright on the table of an arbor press with the threaded end
downward. Place the threaded rotor hub into a hole drilled into
a at, smooth block so that the Rotor rests at on the large rotor
body. Press the Rear Rotor Bearing onto the hub of the Rotor.
Install the Rear Rotor Bearing Retainer (24) in the groove on the
hub of the Rotor.
Install the Front End Plate (29), counterbored end trailing, onto
the threaded hub of the Rotor. Using nger pressure, press the
Front Seal Cup Assembly (31), felt end trailing, onto the end of
the Front End Plate Spacer (30) that is opposite the large internal
bevel. Continue pressing until the felt end is ush with the end of
the Spacer. Saturate the felt with Ingersoll Rand No. 50 Oil. Place
the assembled Spacer, Seal Assembly trailing, onto the threaded
hub of the Rotor. Make sure the Seal Assembly enters the recess in
the Front End Plate.
NOTICE
Before performing the next step, be aware that the Front Rotor
Bearing is a ush ground bearing and must be installed in a
specic manner. The end of the Bearing with a stain or hash
marks must be away from the Spacer.
4. Stand the small hub of the Rotor on the table of an arbor press
with the threaded end upward and press the Front Rotor Bearing
(32) onto the hub of the Rotor.
5. Grasp the assembled Rotor in soft-sided vise jaws with the
threaded rotor hub upward.
6. Thread the Bevel Pinion (66) or Spindle Bearing Nut (59 or 41)
onto the Rotor and using a torque wrench, tighten the Pinion or
Nut between 14 and 19 ft-lb (19.0 and 25.8 Nm) torque.
7. Inject approximately 0.7 cm3 of Ingersoll Rand No. 68 Grease into
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the small recess at the bottom of the Cylinder (17). Drop the two
Rear Rotor Bearing Spacers (26) into the bottom of the Cylinder.
8. Wipe each Vane (28) with a light lm of oil and insert Vane into
each vane slot in the Rotor. Be sure that logo on Vane faces to the
left inside the vane slot when looking down length of Rotor, with
threaded end away.
9. Grasp the Bevel Pinion or Spindle Bearing Nut and insert the
assembled Rotor into the Cylinder.
10. Assemble the Front Muer (33) into the Front Housing Cap (34).
Ensure muer is installed in the Cap and does not get pushed
down into the Motor Housing.
11. Assemble Front Housing Cap onto Motor Housing (12), aligning
notches on Cap with notches in the Cylinder. Place Flange Clamp
(35) in groove in Cap.
Assembly of the Extension Housing on G2E and G2L
Models.
For G2E Models, if the Rear Spindle Bearing (44) was replaced,
proceed as follows:
a. Stand the Extension Housing (43) on the table of an arbor press
with the small end downward.
b. Press the Bearing into the Housing until the trailing end of the
Bearing is 1.408” to 1.418”(35.7 mm to 36.0 mm) below the face
of the large end of the Extension Housing.
2. If the Front Spindle Bearing (46) was replaced, stand the Spindle
(45) on the table of an arbor press, small threaded end upward.
Being careful not to damage the threads on the large end of the
Spindle, press the Bearing, stained or marked end trailing, onto
the Spindle until it seats against the shoulder of the shaft.
3. Using an adjustable wrench on the ats of the Spindle and a
9/16”wrench on the Bevel Pinion (47), thread the Pinion onto the
Spindle against the Bearing and tighten it between 14 and 19
ft–lb (19.0 and 25.8 Nm) torque.
4. Using an adjustable wrench on the Spindle and a 1/2”wrench
on one of the Spindle Bearing Nuts (41), thread Nut without the
Coupling Retaining Ring (42), counterbored end leading, onto the
Spindle. Tighten the Nut between 14 and 19 ft–lb (19.0 and 25.8
Nm) torque.
5. Insert the assembled Spindle, Nut end leading, into the small end
of the Extension Housing. Push the assembly into the Housing
until the Front Spindle Bearing bottoms on the housing shoulder.
6. Using snap ring pliers, install the Coupling Retaining Ring on
the Spindle Bearing Nut protruding into the large end of the
Extension Housing.
7. Grasp the assembled Motor Housing, mounted in Clamp Tool
(96), in soft-sided vise jaws with the Spindle Bearing Nut (41)
upward. Coat the inside of the Arbor Coupling 04581245_ed1
EN-4 EN (39) with approximately 1 cm3 of Ingersoll Rand No. 68
Grease and install the Coupling over the Bearing Nut. Position the
Clamp Sleeve (40) over the Coupling in the ;Motor Housing.
8. Insert the Spindle Bearing Nut in the assembled Extension
Housing into the Arbor Coupling and thread the Extension
Housing onto the Cylinder. This is a lefthand thread; rotate the
Extension Housing counterclockwise to tighten it. Tighten the
Housing between 20 to 25 ft-lb (27.1 to 33.9 Nm) torque.
9. For G2L Models, if the Rear Spindle Bearing (62) was replaced,
stand the Spindle (64) on the table of an arbor press and being
careful not to damage the threads on the Spindle, press the
Bearing onto the Spindle until it seats against the shoulder of the
shaft.
10. If the Front Spindle Bearing (65) was replaced, invert the Spindle
on the table of an arbor press and being careful not to damage
the threads on the Spindle, press the Bearing, stained or marked
end trailing, onto the Spindle until it seats against the shoulder of
the shaft.
11. Grasp a 5/32”diameter steel pin vertically in a set of vise jaws and
slide the crosshole of the Spindle down onto the pin.
12. Using a 9/16”wrench on the ats of the Bevel Pinion (66), thread
the Pinion onto the Spindle against the Bearing and tighten it
between 14 and 19 ft–lb (19.0 and 25.8 Nm) torque.
1.

04581245_ed2 5
13. Using a 1/2”wrench on one of the Spindle Bearing Nuts
(59), thread the Nut with the Coupling Retaining Ring (60),
counterbored end leading, onto the Spindle. Tighten the Nut
between 14 and 19 ft–lb (19.0 and 25.8 Nm) torque.
14. Install the two Rear Spindle Bearing Washers (63) in the Extension
Housing in the rear spindle bearing cavity.
15. Insert the assembled Spindle, Nut end leading, into the small end
of the Extension Housing. Push the assembly into the Housing
until the Rear Spindle Bearing bottoms against the Rear Spindle
Bearing Washers.
16. Grasp the assembled Motor Housing, mounted in Clamp Tool
(96), in soft-sided vise jaws with the Spindle Bearing Nut upward.
Coat the inside of the Arbor Coupling (57) with approximately 1
cm3 of Ingersoll Rand No. 68 Grease and install the Coupling over
the Bearing Nut. Position the Clamp Sleeve (58) over the Coupling
in the Motor Housing.
17. Insert the Spindle Bearing Nut in the assembled Extension
Housing into the Arbor Coupling and thread the Extension
Housing onto the Motor Housing. This is a left-hand thread; rotate
the Extension Housing counterclockwise to tighten it. Tighten the
Housing between 20 and 25 ft–lb (27.1 and 33.9 Nm) torque.
Assembly of the Angle Head
If the Upper Arbor Bearing (52 or 71) was removed and a new
Bearing must be installed, proceed as follows:
a. Support the machined face of the Angle Head (48 or 67) on
the table of an arbor press with the upper arbor bearing bore
upward.
NOTICE
When installing the Bearing in the next step, always press on the
stamped or closed end of the Bearing.
NOTICE
Do not press the Upper Arbor Bearing ush with the top of the
Angle Housing. Press the Bearing to the dimensions given in the
following step.
b. Press a new Upper Arbor Bearing into the bore.
PRESS IN UPPER ARBOR BEARING
TO DIMENSION SHOWN
1.002
.997
2. If the Lower Arbor Bearing (55 or 74) is being installed, it is
necessary to note the identication marks on the Lower Arbor
Bearing. One side of the Bearing has stains or hash marks across
the inner and outer races. Using a sleeve that contacts the inner
ring of the Lower Arbor Bearing, press the Bearing, stain or hash
mark side leading, onto the Arbor (76).
NOTICE
The Bevel Gear and Bevel Pinion in the next step are specially
matched sets. Some sets are color coded for manufacturing
purposes only. Only the Gear and Pinion set furnished as a
replacement part or the same Gear and Pinion set removed from
one tool is a matched set. A Bevel Gear from one tool and a Bevel
Pinion from another tool with the same color code IS NOT A
MATCHED SET. Replace these parts only as a matched set. Failure
to do so will result in unsatisfactory tool performance and
damage to the Bevel Gear and Bevel Pinion.
1.
3. Slide the Bevel Gear (47 or 66), geared face trailing, onto the small
threaded end of the Arbor, aligning the integral keys or spline of
the Gear with the slotted keyways or spline in the Arbor.
4. Thoroughly clean the small threads on the Arbor above the Bevel
Gear and the threads in the Bevel Gear Nut (54 or 73).
5. Apply a thin coat of Loctite 277* (M. I. Hernon Grade 429) to the
threads of the Bevel Gear Nut and the Nut threads on the Arbor.
Thread the Bevel Gear Nut onto the Arbor to retain the Bevel Gear
and tighten the Nut to 8 to 9 ft-lb (10.8 to 12.2 Nm) torque.
6. Form the Wick (53 or 72) into a horseshoe shape and fully insert it
into the U-shaped cavity in the Angle Head. If installing one of the
Wicks having a notch on one side, make certain the notch enters
the Housing rst. Saturate the Wick with approximately 1.5 cm3
of Ingersoll Rand No. 63 Oil. Do not substitute any other oil.
7. Inject 3 cm3 of Ingersoll Rand No. 67 Grease into the Upper
Arbor Bearing and Wick cavity in the Angle Head. Do not
substitute any other grease.
8. Carefully grasp the assembled Motor Housing, mounted in Clamp
Tool in soft-sided vise jaws with the Throttle Lever downward.
9. Install the motor Clamp Nut (50 or 69), threaded end trailing, onto
the motor end of the Angle Head. Spread the Clamp Spacer (49 or
68) and install it, beveled end trailing, onto the motor end of the
Angle Head against the Clamp Nut.
10. Position the output end of the Angle Head upward and 180
degrees opposite to the Throttle Lever and thread the Clamp
Nut onto the Cylinder or Extension Housing. Using the Clamp
Nut Wrench (95), tighten the Nut to 20 to 25 ft-lb (27 to 34 Nm)
torque. This is a left-hand thread, turn counterclockwise to
tighten.
11. Thoroughly clean the internal threads of the Angle Head and the
threads on the Arbor Bearing Cap (56 or 75).
12. Insert the assembled Arbor into the Angle Head, bevel gear
end rst, making sure the teeth on the Bevel Gear and Pinion
mesh. Rotate the Arbor manually to determine they are rotating
smoothly.
13. Carefully apply a thin coat of Loctite 277 to both sets of threads.
14. For G2A and G2L models, using a spanner wrench, install
the Arbor Bearing Cap and tighten to 12 to 15 ft-lb (16.2 to
20.3 Nm) torque. The Bearing Cap has a lefthand thread: turn
counterclockwise to install. For G2E models, using the Arbor
Bearing Cap Wrench (92), install the Arbor Bearing Cap and
tighten to 12 to 15 ft-lb (16.2 to 20.3 Nm) torque.The Bearing Cap
has a lefthand thread: turn counterclockwise to install.
Assembly Instructions for All Collet Models
Install the Collet (77) into the end of the Arbor.
Using the Collet Body Wrench (89) to hold the Arbor, thread the
Collet Nut (78) onto the Arbor.
Assembly Instructions for All Wheel Models
Position the Wheel Guard (81) against the at face of the Guard
Adapter Assembly (79) and using a 1/8”hex wrench, install the
three Guard Mounting Screws (83) and Lock Washers (82). Tighten
the Screws to 2.5 to 3.0 ft-lb (3.4 to 4.1 Nm) torque. For Models
Ending in P96 and P106, Guard is only available as an assembly
and is mounted on the Guard Adapter with permanent thread
locker on the Guard Mounting Screws.
Position the Guard Adapter Assembly (79) recessed surface
leading, on the hub at the spindle end of the Angle Head and
using a 9/64”hex wrench, tighten the Wheel Guard Adapter Screw
(80) to 6 to 6.5 ft-lb (8.1 to 8.8 Nm) torque.
For Models, ending in P63, P64 and P74, thread the Flange
Spacer (86) onto the Arbor and using the Arbor Wrench (91) to
hold the Arbor, tighten the Spacer with the second Arbor Wrench
(89).
For Models ending in P63, P64, P74, P1045, P105, and P106,
install Flange Spacer (86) (P1045, P105 and P106 models only),
the Wheel Flange (84), wheel and Flange Nut (85) on the Arbor.
Use the Arbor Wrench (91) to hold the Arbor while tightening the
Flange Nut with the Flange Nut Wrench (93).
For models ending in P945, P95 and P96, install the Wheel
1.
2.
1.
2.
3.
4.
5.

6 04581245_ed2
Flange (84), wheel, Flange Nut (85). Install the Wheel Retaining
Screw Washer (88) in the recess in the Wheel Flange and install the
Wheel Retaining Screw (87) in the end of the Arbor and tighten
it securely.
For models ending in H64, install wheel against at face on
6.
Arbor and install the Flange Nut (85).
Assembly Instructions for Ergo Handle
Thread the Ergo Handle (75A) into the Angle Housing (67).
Troubleshooting Guide
Troubleshooting Guide
Trouble Probable Cause Solution
Low power or low free speed Insucient air pressure. Check air line pressure at the Inlet of the Tool. It
must be 90 psig (6.2 bar/620 kPa).
Clogged muer elements. Disassemble the Inlet and remove Exhaust
Diuser to replace Muers for Rear Exhaust.
Disassemble Front Clamp Nut and remove Front
Cap for Front Exhaust. Ensure muer is in Front
Cap and not pushed down into Motor Housing.
Plugged Inlet Screen. Clean the Inlet Screen with a clean, suitable
cleaning solution or replace the Screen.
Worn or broken Vanes. Install a complete set of new Vanes.
Loose Clamp Nut or Arbor Housing. Tighten the Nut or Housing between 20 and 25
ftlb (27 and 34 Nm) torque.
Worn or broken Motor Housing Replace the Motor Housing.
Grit buildup under the Throttle Lever
restricting full Throttle Valve Plunger
movement
Remove the Throttle Lever and clean the groove
in the Motor Housing.
Bent stem on Throttle Valve. Replace the Throttle Valve.
Front Seal Cup Assembly dragging
against the shield of the Front Rotor
Bearing
Reposition the Front Seal Cup Assembly.
Excessive runout Bent Arbor. Replace the Arbor.
Loose Collet Nut. Tighten the Collet Nut until snug.
Worn or damaged Collet, Collet Nut or
Nosepiece.
Replace the damaged component and retest.
Worn or damaged Upper Arbor Bearing
or Lower Arbor Bearing.
Replace the worn or damaged Bearing.
Scoring of End Plate Worn Front End Plate Spacer or Front End
Plate.
Install a new Front End Plate Spacer and Front
End Plate.
Worn Front Rotor Bearing. Install a new Front Rotor Bearing.
Leaky Throttle Valve Dirt accumulation on Throttle Valve or
Throttle Valve Seat.
Disassemble, inspect and clean parts.
Worn Throttle Valve or Throttle Valve
Seat.
Replace the Throttle Valve and/or Throttle
Valve Seat.
Excessive dirt build-up beneath the
Throttle Lever.
Clean out the slot area.
Bent Throttle Valve Plunger. Replace the Plunger.

04581245_ed2 7
Trouble Probable Cause Solution
Exhausts at wrong direction Incorrect orientation of the Flow Guide. Reverse the Flow Guide inside the Motor
Housing.
Front Rotor Bearing runs hot Incorrect installation of the Front Seal
Cup Assembly.
Reposition the Front Seal Cup Assembly ush
with the face of the Front End Plate Spacer.
Front End Plate Spacer rubbing the bore
of the Front End Plate.
Replace the Front End Plate and Front End Plate
Spacer combination.
Incorrect Front Rotor Bearing installation
orientation.
If a black stain or black hashmarks are not visible
on the face of the Bearing when it is assembled
with the End Plate and Rotor, the Bearing is
installed backwards. If possible, remove the
Bearing and install it correctly or replace the
Bearing.
Slow tool idle Bent or leaky Throttle Valve. Replace the Throttle Valve.
Rough operation/vibration Improper lubrication or dirt buildup. Disassemble the Tool and clean in a suitable
cleaning solution. Assemble the Tool and
inject 3 cm3 of the recommended oil into the
Inlet and run the tool long enough to coat the
internal parts with the oil.
Worn or broken Rear Rotor Bearing or
Front Rotor Bearing.
Replace the worn or broken Bearings. Examine
the Front End Plate, Front End Plate Spacer
Front Seal Cup Assembly and Rear Rotor Bearing
Spacers and replace any damaged parts. If the
rear end plate is damaged, replace the Rotor.
Worn or broken Upper Arbor Bearing or
Lower Arbor Bearing.
Replace the worn or broken Bearing.
Worn or broken Bevel Gear or Bevel
Pinion.
Examine the Bevel Gear and Bevel Pinion. If
either is worn or damaged, replace both the
Gear and the Pinion because they are a matched
set and must not be used separately.
Related Documentation
For additional information refer to:
Air Grinder Product Safety Information Manual Form 04584959.
Air Die Grinder Safety Information Form 04580288.
Air Sander Safety Information Form 04580387.
Product Information Manual Form 04581211, Form 04581799, Form 04581195 and Form 04581203.
Parts Information Manual Form 04581237.
Manuals can be downloaded from ingersollrandproducts.com

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