Ingersoll-Rand 99HL60H106-EU Setup guide

16573354
Edition 2
February 2014
Save These Instructions
Air Grinder
Series 99H
Maintenance Information

2 16573354_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).
Lubrication
•
•
•
•
•
Whenever a Series 99H Grinder is disassembled for overhaul or
replacement of parts, lubricate as follows:
Inject about 1.5 cc of Ingersoll Rand No. 50 Oil into the Inlet
Bushing (4) after assembly. Fill the oil chamber. After each eight
hours of operation, replenish the oil supply. The use of an air line
lubricator is recommended with these grinders.
Where the lubricator cannot be permanently mounted, we
recommend using Ingersoll Rand No. 8LUB12 Lubricator. For
permanent installations, we recommend using Ingersoll Rand
No. C31-06-G00 Filter-Lubricator-Regulator Unit. These units have
3/4” pipe tap, 1/2 pt. (237 ml) capacity. Larger capacity units may
be used, but do not use a unit having less than a 3/4”pipe tap inlet
and outlet.
Oiler Adjustment
The built-in lubricator has been properly adjusted at the factory.
A lack of oil indicates the Oiler needs lling or the Oiler Felts (21) are
clogged and must be replaced as follows:
For Grip Handle Models
Remove the Arbor Housing Screws (30), Lock Washers (31) and
Arbor Housing Gasket (32).
Remove the Oil Chamber Plug (24) and pour the oil from the oil
chamber.
Using snap ring pliers remove the Oiler Retainer (18).
Insert a 1/4 x 20 (M6 x 1.0) machine screw in the pilot hole of the
Oiler Body Assembly (19). (Refer to Dwg. TPD638.)
(Dwg. TPD638)
1.
2.
3.
4.
5. Grasping the screw head with pliers, pull out the Oiler
Body Assembly.
6. With a thin-blade screwdriver, unscrew the Oiler Adjusting
Screw (20).
7. Using tweezers or a piece of bent wire, remove the Oiler Felts (21)
and install a new set.
8. Replace the Oiler Adjusting Screw, installing it slightly below
ush.
9. Replenish the oil supply.
For Lever Handle Models
Remove the Arbor Housing Screws (30), Lock Washers (31) and
Arbor Housing Gasket (32).
Remove the Oil Chamber Plug (24) and pour the oil from the oil
chamber.
Using snap ring pliers, remove the Oiler Retainer (18).
Insert lock ring pliers in the hole of the Oiler Body Assembly (19)
and pull out the Oiler Body Assembly.
With a thin-blade screwdriver, unscrew the Oiler Adjusting
Screw (20).
Using tweezers or a piece of bent wire, remove the Oiler Felts and
install a new set.
Replace the Oiler Adjusting Screw, installing it slightly below ush.
Replenish the oil supply.
1.
2.
3.
4.
5.
6.
7.
8.
Disassembly
General Instructions
Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
Whenever grasping a tool or part in a vise, always use
leather-covered or copper-covered vise jaws to protect the
surface of the part and help prevent distortion. This is particularly
true of threaded members and housings.
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 replacements.
1.
2.
3.
4.
Disassembly of the Arbor
Grasp the Arbor Housing (29) in a vise, guard upward.
Use an appropriate spanner wrench inserted into the pinhole of
the ange to hold the Arbor. Unscrew the Wheel Nut (51) with an
open-end wrench. Remove the Wheel Flanges (52).
Unscrew the Guard Screws (53). Remove the Guard Screw Lock
Washer (54) and the Wheel Guard (55).
Lift the Arbor (56) and the Arbor Coupling (50) from the Arbor
Housing. Pull the Arbor Coupling o the Arbor.
Grasp the Arbor in a vise, spline end up.
With pliers, straighten the tangs of the Bearing Lock Washer (58).
Unscrew the Bearing Locknut (57) and remove the Bearing Lock Washer.
If the Arbor Bearing (59) is to be replaced, press it from the arbor shaft.
1.
2.
3.
4.
5.
6.
7.

16573354_ed2 3
Disassembly of the Motor and Throttle
Using the No. R2J-562 Deector Screw Wrench, remove
the Exhaust Deector Screws (28) and lift o the Exhaust
Deector (25), Exhaust Deector Gasket (26A), Exhaust
Diuser (27) in models where used and Exhaust Bae (26).
Grasp the Arbor Housing (29) in a vise.
Unscrew the Arbor Housing Screws (30) and remove the Lock
Washers (31).
Lift o the Throttle Handle Assembly (1) to expose the motor.
Remove the Arbor Housing Gasket (32).
Grasp the Controller Assembly (35) by hand and pull the motor
unit out of the Arbor Housing.
Remove the Arbor Housing from the vise. Turn over the Arbor
Housing and the two Motor Clamp Washers (49) will drop out.
Grasp the Rotor Shaft (48) in the vise.
Remove the Controller Retaining Nut (34) and unscrew the
Controller Assembly.
CAUTION
Use only the special 99V60-950 Controller Wrench for removing
the Controller Assembly. Do not attempt to disassemble the
Controller. It is available only as a unit and is guaranteed for the
life of the tool if it is not abused.
10. Lift o the Rear End Plate Gasket (33).
11. Set the Bearing Cage (37) on blocks in an arbor press. Using a
metal sleeve tting the inner race of the Rear Rotor Bearing (36),
press o the Bearing Cage.
12. If the Rear Rotor Bearing needs to be replaced, insert the
Rear Rotor Bearing into the 99V60-A952 Bearing Clamp and
1.
2.
3.
4.
5.
6.
7.
8.
9.
tighten the nut on the xture. Insert the 99V60-951 Seal Pressing
Tool in the center of the Rear Rotor Bearing and press o the
Controller. Release the clamp.
13. Lift o the Rotor Bearing Seal (36), and Rear End Plate (39).
14. Lift o the Cylinder (40).
15. Remove the Vanes (44).
16. Withdraw the Rotor (43) and lift out the Rotor Key (45).
17. Remove the rotor shaft and end plate assembly from the vise.
Grasp the Front End Plate (46) in one hand and tap the small
diameter end of the rotor shaft with a soft hammer to remove the
end plate.
18. If the Front Rotor Bearing (47) is to be replaced, press it from the
rotor shaft.
19. Unscrew the Oil Chamber Plug from the Throttle Handle
Assembly and pour the oil from its reservoir.
20. Place the Throttle Handle Assembly in a vise to remove the Inlet
Bushing (4), Inlet Bushing Screen (5) and the Throttle Valve
Spring (6). The Bushing has an interference thread and is tightly
t.
21. Drive out the Throttle Lever Pin (13) to release Lever
Assembly (14).
22. Remove the Throttle Valve Spring (6) and release the Throttle
Valve (2) by tapping the end of the handle with a soft hammer or
by using lock ring pliers.
23. Release the Throttle Valve Seat Support Assembly (7) by tapping
the end of the handle with a soft hammer.
24. Remove the Valve Seat Screw (8), Valve Screw Lock Washer (9),
Valve Seat Washer (10) and Valve Seat (11). The Air Strainer
Screen (12) may now be cleaned.
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 in a bearing recess.
Whenever grasping a tool or part in a vise, always use
leather-covered or copper-covered vise jaws to protect the
surface of the part and help prevent distortion. This is particularly
true of threaded members and housings.
Always clean every part, and wipe every part with a thin lm of oil
before installation.
Apply a lm of O-ring Lubricant to all O-rings before installation.
Assembly of the Throttle and Inlet
Assemble the Valve Seat Support Parts. Tighten the Valve Seat
Screw (8) to 12 in-lb (1.4 Nm) torque.
Insert the Assembly in the handle, large diameter rst. Locate a
punch on the at of the screw head and tap it with a hammer
until the assembly is rmly seated.
Apply O-ring lubricant to the Seals (3). Fit the seals to the Throttle
Valve (2) and push the assembly, small diameter rst, into the
handle until it seats rmly.
Assemble the Locking Lever Assembly (14) as illustrated in
Dwgs. TPD563 and TPD646.
1.
2.
3.
4.
5.
1.
2.
3.
4.
For Lever Handle Models
(Dwg. TPD563)
For Grip Handle Models
(Dwg. TPD646)
Assembly

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5. Align the holes in the Lever Assembly with the slots in the
Throttle Handle. With a soft hammer, tap the Throttle Lever
Pin (15) through the Lever Assembly. File o any sharp edges.
Operate the mechanism internally by hand to assure operation.
6. Grasp the Throttle Handle in a vise.
7. Insert the Throttle Valve Spring (6) small end rst.
8. Clean the face of the Inlet Bushing (4) and the Inlet Bushing
Screen (5) with a suitable cleaning solution in a well-ventilated
area before assembling into the tool. Insert the parts in the end of
the Throttle Handle. With a Wrench tighten the Inlet Bushing (4)
between 35 and 45 ft-lb (47 and 61 Nm) torque.
Assembly of the Motor
Using an arbor press, press against the inner race of the bearing
to install the Front Rotor Bearing (47) onto the Rotor Shaft (48).
Inspect the Front End Plate (46) for nicks or burrs. Replace if
necessary. Install the Front End Plate over the Rotor Shaft (48) and
onto the Front Rotor Bearing (47). This is a light press t.
Hold the Rotor Shaft in a vise. Insert the Rotor Key (45) in the slot
of the Rotor (43). The Rotor is counterbored on one end. Place
that end over the Rotor Shaft.
NOTICE
This should be a slip t. If tightness is detected, lightly polish
one long side of the Rotor Key using ne emery cloth on a hard,
at surface. Insert the key with the polished side toward the
Rotor Shaft.
Apply a light lm of the recommended oil to each Vane (44) and
insert one vane, straight edge out, into each slot in the Rotor.
If any new vanes are required, replace the entire set.
4. Place the Cylinder (40) over the Rotor matching the End Plate
Dowel (short dowel) (41) to the alignment hole in the Front End
Plate (46).
5. Align the Rear End Plate (39) with the Long Cylinder Dowel (42).
NOTICE
If the Controller Assembly (35) needs to be replaced, you must
also replace the Rotor Bearing Seal Assembly (36) which consists
of the Rear Rotor Bearing and Rotor Bearing Seal. If either the
Rear Rotor Bearing or Rotor Bearing Seal needs to be replaced,
BOTH must be replaced with a new Bearing and Seal. Do not mix
old and new parts.
6. Check the outside diameter and large inside diameter of the
Rotor Bearing Seal for wear. If the outside diameter of the hub
is worn to 1.176”(29.9 mm) or smaller, and/or the large inside
diameter is worn to 0.91”(23.1 mm) or larger, install a new Rotor
Bearing Seal Assembly.
NOTICE
Take all measurements 90 degrees to the left of the dowel hole
when facing the hub side of the Seal.
Install the Rotor Bearing Seal.
7. Press the Rear Rotor Bearing (36) onto the hub of the Controller
and press the Controller Assembly into the Bearing Cage (37) to
within 1/8” of seating.
8. Slip the Controller Assembly over the Rotor Shaft. Rotate the
Controller counterclockwise since this is a left-hand thread.
CAUTION
Use only the special No. 99V60-950 Controller Wrench for
applying the assembly.
1.
2.
3.
WARNING
Tighten the Controller to 14 to 16 ft-lb (19.0 to 21.7 Nm) torque.
Do not exceed 16 ft-lb. The Controller may be damaged if this
torque is exceeded.
Always check the free speed of a Grinder after it has been
reassembled and before it is put back into service. Refer to Test
Procedure.
Never use a Grinder which runs in excess of the maximum speed
listed in the Test and Inspection Procedure.
NOTICE
The Controller Retaining Nut (34) has a right-hand thread.
9.
Install the Controller Retaining Nut. Tighten to 9 ft-lb (12.2 Nm) torque.
10. Grasp the Throttle Handle Assembly (1) in a vise, wide end up
with the Throttle Lever facing right.
11. Insert the assembled motor into the Throttle Handle Assembly
aligning the Cylinder Dowel with the upper left-hand dowel pin
hole.
12. Lightly dampen the Arbor Housing Gasket (32) with oil and align
it with the holes in the Throttle Handle Assembly.
13. Insert the two Motor Clamp Washers (49) over the spline of the
Rotor Shaft, concave side up so the inner rim contacts the Front
End Plate (46).
14. Place the Arbor Housing (29) onto the Throttle Handle Assembly.
NOTICE
Make sure THE NOTCH on the face of the Arbor Housing lines up
with the Cylinder Dowel of the motor. Exhaust will be to the right
of the operator.
NOTICE
Rotating the housing and motor and aligning the Cylinder
Dowel with each of the dowel pin holes changes the direction of
exhaust 90 degrees.
15. Place Lock Washers on the Arbor Housing Screws (30) and slightly
tighten opposite screws; then tighten all screws to 14 ft-lb
(19 Nm) torque.
16. Install the Exhaust Bae (26), Exhaust Diuser (27) in models
where used and the Exhaust Deector (25) and Exhaust Deector
Gasket (26A) in the Arbor Housing. Insert the Exhaust Deector
Screws (28) and tighten with the No. R2J-562 Deector Screw
Wrench to 23 in-lb (2.6 Nm) torque.
Assembly of the Arbor
Press the Arbor Bearing (59) onto the Arbor Shaft (56).
Grasp the Arbor Shaft in a vise, spline end up.
Install the Bearing Lock Washer (58) and Bearing Locknut (57).
Tighten the Locknut snugly. Bend the tangs of the Bearing
Lock Washer into the grooves of the Bearing Locknut.
Remove the Arbor Shaft from the vise.
Grasp the Arbor Housing (29) in a vise, Guard end up.
Coat the spline of the Rotor Shaft and the spline of the Arbor
Shaft with 3 to 4 cc of Ingersoll Rand No. 28 Grease. Insert the
Arbor Coupling into the Arbor Housing and onto the spline of
the Rotor Shaft. Slip the spline of the Arbor Shaft into the Arbor
Coupling.
Place the Wheel Guard (55) onto the Arbor Housing making sure
the holes are aligned. Install the Guard Screw Lock Washers (54)
and Guard Screws (53). Tighten to 15 ft-lb (20.3 Nm) torque.
Install a Wheel Flange (52), Wheel and the other Wheel Flange (52)
onto the Arbor (56).
1.
2.
3.
4.
5.
6.
7.
8.

16573354_ed2 5
NOTICE
Slip the anges onto the arbor so the keys are opposite each
other.
9. Using an applicable Spanner Wrench inserted into the pin hole
of the ange to hold the arbor, install the Wheel Nut (51) with an
open-end wrench. Only tighten suciently to drive the wheel
and prevent slippage.
10. Fill the oil chamber with the recommended oil and insert the Oil
Chamber Plug (24). Tighten to 4 ft-lb (5.4 Nm) torque.
Test and Inspection Procedure
WARNING
Disconnect the grinder from the air supply hose and shut o
air to the tool before proceeding with the Test and Inspection
Procedure.
Run the performance tests at 90 psig (6.2 bar/620 kPa) air pressure at
the inlet of the tool with an eight foot (2.44 m) length of 3/4”(19 mm)
diameter air supply hose.
Without a wheel on the tool, operate the Grinder with the Throttle
Lever fully depressed and check the free speed by applying a
hand-held techometer to the spindle end. The minimum and
maximum allowable free speeds are as follows:
Model Stamped Free Speed
Minimum Maximum
99H45
99H60
4500
6000
4300
5630
4550
6050
2. Test the Grinder Motor for power to determine these minimum
performance levels. The Throttle Lever must not be actuated
repeatedly during the test. Depress the Lever and hold it in the
open position until the test is complete.
1.
Model
Torque
Speed, rpm(r/min)
ft-lb Nm
99H45
99H60
3.80
3.50
5.2
4.7
3300
4400
3. There must be no objectionable leaks in any non-exhaust area.
The Throttle must not leak when it is closed.
4. There must be no leaks past the closed Throttle that will run the
motor.
5. The Grinder must start smoothly when the Throttle Lever is
depressed and must shut o completely when the Throttle Lever
is released.
6. The Grinder must be equipped with a spring-loaded window
style Lock (17). The Lock must return to the locked position when
the Throttle Lever is released.
7. The tool must run smoothly without noticeable vibration or
unusual sound.
8. The Arbor (58 or 59) must turn freely with no evidence of
brinelled bearings.
9. The Threads on the arbor must be free of nicks and damage.
10. The Nameplate must be legible, in place and securely fastened.
Make replacement if necessary.

6 16573354_ed2
Troubleshooting Guide
Trouble Probable Cause Solution
Low power or low free speed Low air pressure at the Inlet of the Grinder Check the air pressure at the Inlet. For maximum performance
and durability of parts, the pressure must not exceed 90 psig
(6.2 bar/620 kPa).
Plugged Screens Clean the Screen in a clean, suitable cleaning solution in a well
ventilated area. If it cannot be cleaned, replace it.
WARNING
Never operate a Grinder without an inlet screen. Ingestion
of dirt into the Grinder can, in some cases, cause an unsafe
condition.
Worn or broken Vanes Replace a complete set of Vanes.
Worn of broken Cylinder Replace the Cylinder if it appears cracked or if the bore is wavy
or scored.
Improper lubrication or dirt build-up in
the motor
Lubricate the Grinder as instructed in LUBRICATION.
If lubrication does not result in satisfactory operation,
disassemble the motor, inspect and clean all parts.
High free speed Worn Rotor Bearing Seal Replace the Rotor Bearing Seal Assembly if the outside
diameter of the hub is worn to 1.176” (29.9 mm) or smaller
and/or the large inside diameter is worn to 0.91”(23.1 mm)
or larger.
Rough operation Worn or broken Rear Rotor
Bearing or Front Rotor Bearing
Examine each Bearing. Replace Rotor Bearing Seal Assembly or
Front Rotor Bearing if worn or damaged.
Worn Rotor Key Replace the Key. Check the Rotor Shaft or Rotor for key slot
wear and replace if necessary.
Bent Arbor Mount the Arbor on centers. Check the bearing diameter for
runout with an indicator. Replace the Arbor if runout exceeds
0.002” (0.051 mm) Total
Indicator Reading.
Scoring Improper assembly Make certain that all motor parts are properly aligned prior to
clamping the motor assembly.
Air Leaks Worn Valve Seat or Valve Seat Washer Replace worn parts.
Worn Throttle Valve Seals Replace both Seals.
Worn Arbor Housing Gasket Replace the Gasket
Oiler Plug worn or not tight Tighten the Plug. If the problem persists, replace the Plug.
Related Documentation
For additional information refer to:
Product Safety Information Manual 04584959.
Product Information Manual 16573214 and 16576100.
Parts Information Manual 16573297.
Manuals can be downloaded from ingersollrandproducts.com.

Notes

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