Ingersoll-Rand DG600G2 Series Setup guide

16574949
Edition 2
February 2014
Save These Instructions
Pencil Grinders
DG600G2 Series
Maintenance Information

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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
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Whenever one of these Grinders is disassembled for overhaul or
replacement of parts, lubricate as follows:
Always wipe the Blades (23) with a light lm of the recommended
oil before inserting them into the vane slots.
1.
Inject 0.5 to 1 cc of Ingersoll Rand Lubricant No. 10 or a good
quality high-speed spindle oil into the Valve Body (6) after
assembly.
2.
Disassembly
The Model DG600G2 Pencil Grinder can be disassembled into
three major unit assemblies. They are the Valve Body Assembly (4),
the Motor Assembly (17) and the Air Block Assembly (13). Do not
disassemble any major unit assembly that does not require repair.
General Disassembly 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 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.
Disassembly of the Tool
Remove Snap Ring (1) and Exhaust Sleeve (2), allowing removal of
Hose Assembly (3).
CAUTION
Do not grasp the Motor Housing (28) with pliers or in a vise.
2. Carefully grasp the ats on the Hose Assembly in a vise.
3. Using 9/16” wrench on ats on the Valve Body, loosen and
remove tool from Hose Assembly.
4. Reposition tool in vise and carefully grasp on the ats of the Valve
Body.
5. Remove Sleeve (29) by twisting and pulling upward.
6. Place tool horizontally in a suitable holding device and clamp on
one of the bottom two grooves of Motor Housing (28).
7. Using 9/16” wrench on ats of Valve Body loosen and remove
from Motor Housing (28).
NOTICE
The Motor Assembly and Air Block Assembly will be free to fall
out of the Motor Housing when the Housing is lifted from the
Valve Body.
1.
2.
1.
8. Remove the Motor Housing from the vise.
Disassembly of the Valve Body
Remove Screen (5).
Remove Throttle (12).
Using a pair of pliers remove Plug (9), being careful not to
damage.
Using needle nose pliers remove Valve (10) from Valve Body.
Remove O-rings (11), if necessary.
Remove Bushing (8) and O-ring (7), if necessary.
NOTICE
Do not disassemble the Rotor components unless damage is
evident.
Disassembly of the Motor
Place Motor Assembly (17) in suitable holding device with Ball
Bearing (18) facing upwards.
Place a punch on the i.d. of the Bearing and tap to remove
Bearing, allowing removal of End Plate (24), Cylinder (21) and
Blades (23).
Place Rotor in special holding device, using wrench 47579 on ats
of Collet body (26) loosen and remove from Rotor (22).
Using a punch, tap on i.d. of Rotor and remove Bearing (25) and
End Plate (24).
Disassembly of the Air Block Assembly
Grasp Air Block Assembly (13) and pull apart from Motor
Assembly.
Remove Screen (15) and Snap Ring (14), if necessary.
1.
2.
3.
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5.
6.
1.
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4.
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2.
Assembly
General Assembly 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 leather-
covered or copper-covered vise jaws. Take extra care with
threaded parts and housings.
1.
2.
3.
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 nal
assembly.
Assembly of the Air Block Assembly
Assemble Snap Ring (14) and Screen (15) to Air Block (13).
Assembly of the Cylinder
Assemble Pin (20) to Cylinder (21).
4.
5.
1.
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Assembly of the Motor
Assemble End Plate (24) to Rotor (22).
Assemble Bearing (25) on Rotor.
Using a special holding device clamp on Rotor and tighten Collet
Body (26) to Rotor.
Screw Insert (27) on Collet Body.
Assemble Blades (23) to Rotor slots on Rotor - straight side out.
Slide Cylinder over Rotor with Pin facing upward.
Assemble End Plate (19) to Rotor (22), aligning hole in End Plate
with Pin (20).
Assemble Bearing (18) to Rotor. Press on inner race of Bearing.
NOTICE
Install Bearing with retainer toward End Plate.
9. Assemble Air Block Assembly (13) by aligning hole in Block with
Cylinder Pin and assemble components to Motor Housing (28).
Assembly of the Valve Body
Apply a thin coat of O-ring lubricant to O-rings (11) and install
them in the grooves in the Valve Body (6).
Assemble O-ring and Bushing (8) in front end of Valve Body (6).
Insert Valve (10) into Valve Body and rotate Valve until the hole
aligns with the slot in the Valve Body.
Insert Plug (9) into hole of Valve.
Slide Throttle (12) over front end of Valve Body.
Insert Screen (5) in rear of Valve Body.
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2.
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6.
Assembly of the Tool
Insert Motor Assembly with Air Block Assembly attached into
Housing (28).
Assemble Throttle (12) to Valve Body.
NOTICE
The Throttle must rotate freely when the tool is completely
assembled.
3. Assemble Valve Body Assembly (4) to Housing.
4. Place tool in special holding device and clamp on one of the
bottom two grooves.
5. Rotate the Throttle to the ON position and tighten Valve Body
Assembly to Housing using a 9/16 inch wrench on ats of Valve
Body.
6. Rotate the Throttle to the OFF position and remove tool from the
special holding device. Grasp Insert Assembly on front end of tool
to ensure tool turns freely.
7. Carefully grasp the ats on the threaded end of the Valve Body in
vise with the Collet Body (26) upward.
8. Lubricate Sleeve (29) and slide over top of tool.
9. Slide Exhaust Sleeve (2) and Snap Ring (1) over Hose
Assembly (3).
10. Remove the assembled tool from the vise and connect the Hose
Assembly to the Valve Body.
11. Slide Exhaust Sleeve to groove in Valve Body and secure Snap
Ring.
1.
2.
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).
Insucient lubrication Inject 0.5 to 1 cc of the recommended oil into the Air Inlet.
Clogged Muer Replace the Muer.
Worn or broken Blades Install a complete set of new Blades.
Worn or broken Cylinder Replace the Cylinder.
Rough operation Improper lubrication or dirt buildup Inject 3 cc of a clean, suitable cleaning solution into the
Inlet, operate the tool for 30 seconds and immediately
inject 0.5 to 1 cc of the recommended oil into the Inlet
and run the Grinder long enough to coat the internal
parts with the oil.
Worn or broken Rear Rotor
Bearing or Front Rotor Bearing
Examine each bearing. Replace the Rear Rotor Bearing if it
is worn or broken. Replace the Rotor Assembly if the front
rotor bearing is worn or broken.
Excessive runout Loose Spindle Nut Tighten the Spindle Nut until snug.
Worn or damaged Spindle or Spindle Nut Replace the damaged component and retest.
Worn or damaged Front Spindle Bearing or
Rear Spindle Bearing
Examine each Bearing. Replace any damaged or worn
Bearings.
Related Documentation
For additional information refer to:
Product Safety Information Manual 04580288.
Product Information Manual 04585170.
Parts Information Manual 16573826.
Manuals can be downloaded from ingersollrandproducts.com.

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