Ingersoll-Rand 20 Series Setup guide

80153448
Edition 1
July 2006
20 Series Power Unit
DLO21B-10-P
Installation and
Maintenance Information
Save These Instructions

280153448_ed1
WARNING
General Product Safety Information
• Important Safety Information enclosed.
• Read and understand this manual before operating this motor.
• It is your responsibility to make this safety information available to others that will operate this motor.
Safety Information - Explanation of Safety Signal
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury or property damage.
Indicates information or a company policy that relates directly or indirectly to the safety of
personnel or protection of property.
DANGER
WARNING
CAUTION
NOTICE
WARNING
Failure to observe the following warnings could result in injury.
• Operate this tool at 90 p.s.i.g. (6.2bar/620 KpA) maximum air pressure at the air inlet of the motor.
• Keep hands, clothing and long hair away from rotating end of the motor.
• Anticipate and be alert for sudden changes in motion during start up and operation of any power tool.
• Never exceed rated r.p.m. of motor.
• Wear suitable eye and hearing protection while operating motor.
• Tool shaft can continue to rotate briefly after throttle is released.
• Do not lubricate tools with flammable or volatile liquids such as kerosene, diesel or jet fuel.
• Do not carry the tool by the Hose.
• Do not use damaged, frayed or deteriorated air hoses and fittings.
• Do not overreach when operating this tool. Keep body stance balanced and firm.
• Do not remove any labels. Replace any damaged label.
• Use only accessories recommended by Ingersoll Rand.
• Repeated prolonged operator exposure to vibrations which may be generated in use of certain hand-held tools may
produce Raynaud’s phenomenon, commonly referred to as Whitefinger disease. The phenomenon produces
numbness and burning sensations in the hand and may cause circulation and nerve damage as well as tissue
necrosis. Repetitive users of hand held tools who experience vibrations should closely monitor duration of use and
their physical condition.
• Air powered tools can vibrate in use. Vibration, repetitive motions or uncomfortable positions may be harmful to
your hands and arms. Stop using any tool if discomfort, tingling feeling or pain occurs. Seek medical advice before
resuming use.
Safety Symbol Identification
(Dwg. MHP2598)
Wear Respiratory
Protection
Wear Eye
Protection
Wear Hearing
Protection
Read Manuals Before
Operating Product

80153448_ed1 3
Routine Lubrication Requirements
Lack of or an excessive amount of lubrication will affect the
performance and life of this tool. Use only recommended
lubricants at below time intervals:
Every 8 Hours of Tool Operation:-
Fill lubricator reservoir of recommended F.R.L. with spindle
oil (29665). If an in line or air line lubricator is not used, apply
several drops of spindle oil (29665) in air inlet.
Every 160 Hours of Tool Operation:-
Lubricate gearing. Pack bearings, coat shafts and lubricate
gears with NLGI #1 “EP” grease (33153). Gearing should
contain approximately 3/64 oz. (1.3 g) of grease.
Air Supply Requirements
For maximum operating efficiency, the following air supply
specifications should be maintained to this air tool:
• Air Pressure - 90 p.s.i.g. (6.2 bar)
• Air Filtration - 50 micron
• Lubricated Air Supply
• Hose Size - 5/16” (8mm) I.D.
An Ingersoll Rand model C28231-810 air line FILTER/
REGULATOR/LUBRICATOR (F.R.L.) is recommended to
maintain the above air supply specifications.
Recommended Lubricants
After disassembly is complete, all parts, except sealed or
shielded bearings, should be washed with solvent. To
relubricate parts, or for routine lubrication, use the following
recommended lubricants:
Inspection, Maintenance and Installation
Disconnect air supply from the tool or shut off air supply and
exhaust (drain) line of compressed air before performing
maintenance or service to the tool.
It is important that the tools be serviced and inspected at
regular intervals for maintaining safe, trouble-free operation
of the tool.
Be sure the tool is receiving adequate lubrication, as failure
to lubricate can create hazardous operating conditions
resulting from excessive wear.
Be sure that the air supply lines and connectors are of proper
size to provide a sufficient quantity of air to the tool.
Tool maintenance and repair shall be performed by
authorized, trained, competent personnel. Tools, hose and
fittings shall be replaced if unsuitable for safe operation and
responsibility should be assigned to be sure that all tools
requiring guards or other safety devices shall be kept in
legible condition. Maintenance and repair records should be
maintained on all tools. Frequency of repair and the nature of
the repairs can reveal unsafe application. Scheduled
maintenance by competent authorized personnel should
detect any mistreatment of abuse of the tool and worn parts.
Corrective action should be taken before returning the tool for
use.
Disassembly should be done on a clean work bench with a
clean cloth spread to prevent the loss of small parts. After
disassembly is completed, all parts should be throughly
washed in a clean solvent, blown dry with air and inspected
for wear levels, abuse and contamination. Double sealed or
shielded bearings should never be placed in solvent unless a
good method of re-lubricating the bearing is available. Open
bearings may be washed but should not be allowed to spin
while being blown dry.
Upon reassembling, lubricate parts where required. Use
33153 grease, or equivalent, in bearings. Use 36460
lubricant for “O” ring assembly. When assembling “O” rings or
parts adjacent “O” rings, care must be excercised to prevent
damage to the rubber sealing surfaces. A small amount of
grease will usually hold steel balls and other small parts in
place while assembling.
When replacement parts are necessary, consult drawing
containing the part for identification.
Always use clean, dry air. Dust, corrosive fumes and/or
excessive moisture can damage the motor of an air tool. An
air line filter can greatly increase the life of an air tool. The
filter removes rust, scale, moisture and other debris from the
air lines. Low air pressure (less than 90 p.s.i.g.) reduces the
speed of the air tool. High air pressure (more than 90 p.s.i.g.)
raises performance beyond the rated capacity of the tool and
could cause injury. Shown below is a typical piping
arrangement.
Dwg. (TPD905-2)
Where Used
Air Motor
"
O" Rings & Lip Seals
Gears and Bearings
Ingersoll Rand Part #
29665
36460
33153
Description
1 qt Spindle Oil
4 oz. Stringy Lubricant
5 lb. "EP" - NLGI # 1 Greas
e
F
LR
Ø
Ø
FRL
Compressor
Drain Regularly
Regulator
Lubricator Filter
Emergency
Shut-Off Valve
To Air Tool
Main Line(s) Inner
to be 3 X Size of
Air Tool’s Inlet
Ø
Ø
Branch Line(s) Inner
to be 2 X Size of
Air Tool’s Inlet

480153448_ed1
20 Series Power Unit Exploded View
Dwg. (16598492)
20 Series Power Unit Parts List
6
15
28
LARGE CHAMFER THIS SIDE
27 26 24 25 24 23 22 21 20 19 18 17
14 13 12 16
11
10
98 7
54 321
Item Part Description Part
Number Item Part Description Part Number
1 Screen 33911 16 Locating Pin 47719-2
2 Inlet Adapter 46377 17 Planet Gear (3 req'd) 21 teeth 46875
3 Diffuser Washer 46371 18 Carrier Assembly 46336
4 Exhaust Cap 46352 19 Sun Gear, 21 teeth 46560
5 Filler (2 req'd) 48199-1 20 Planet Gear (3 req'd) 15 teeth 46904
6 Housing Assembly 04562500 21 Spindle Assembly 47804-2
Motor Assembly 48225-1S 22 Ring Gear 46703
7 Bearing 41643 23 Spacer 46496
8 Rear End Plate 46245 24 Bearing (2 req'd) Y65-13
9 Rotor 46338-2 25 Spacer 46706
10 Blade (5 req'd) 46301 26 Wave Washer 47682
11 Cylinder 48200-1S 27 Lock Nut 46704
12 Front End Plate 47718 28 Spacer 46705
13 Bearing Y65-10 * Warning Label 48176-1
14 "O" Ring Y325-116 * Bail 46328
15 Spacer 46305
* Not Shown

80153448_ed1 5
Disassembly/Assembly Instructions
NOTICE
• Never apply excessive pressure by holding device which
may cause distortion of a part.
• Apply pressure evenly to parts which have a press fit.
• Apply even pressure to the bearing race that will be press
fitted to the mating part.
• Use correct tools and fixtures when servicing this tool.
• Don’t damage “O” rings when servicing this tool.
• Use only genuine Ingersoll Rand replacement parts for
this tool. When ordering, specify part number,
description, tool model number and serial number.
Gearing Disassembly
• Clamp tool in a smooth face vise, clamping on inlet
adapter (2).
• Unthread and remove ring gear (22) and components
from tool using a wrench on flats of ring gear.
• Remove spindles and gears from ring gear.
• Remove lock nut (27), releasing washer (26),
bearings (24) and spacers (25 and 23).
• Do not remove gear (19) from carrier assembly unless
damage is evident. Gear is press fit onto carrier
assembly.
Gearing Assembly
• Assemble spacer (23) and one bearing (24) into
ring gear (22), pressing on outer race of bearing.
• Coat shafts of spindle(s) with Ingersoll Rand 33153
grease.
• Assemble gears to shafts of spindle(s).
• Assemble carrier assembly (18) to spindle assembly (21).
• Lubricate sets of gears liberally with Ingersoll Rand
33153 grease (approximately 1/32 oz. per reduction).
• Assemble spindle(s) and gearing into ring gear. Rotate
spindle and gears to align gear teeth with splines of ring
gear.
• Assemble spacer (25) and bearing (24) into ring gear,
pressing an outer race of bearing.
• Assemble wave washer (26) to ring gear.
• Assemble lock nut (27) to spindle, securing components.
• Assemble ring gear and components to tool and tighten,
using a wrench on flats of ring gear.
• Assemble spacer (28) to tool.
Motor Disassembly
• Remove gearing from tool.
• Remove spacer (15) and “O” ring (14).
• Tap front edge of housing to remove motor assembly.
Locating pin (16) should also come out.
• Grasp cylinder in one hand and tap splined end of
rotor (9) with a soft face hammer; motor will come apart.
• Remove end plate (8) and bearing (7) from rotor.
Motor Assembly
• Pack bearing (7) with Ingersoll Rand 33153 grease and
assemble to end plate (8), pressing on outer race of
bearing.
• Assemble end plate (8) to rotor, pressing on inner race of
bearing.
• Coat five rotor blades (10) with Ingersoll Rand 29665
spindle oil and assemble to rotor slots - straight side out.
• Coat i.d. of cylinder (11) with Ingersoll Rand 29665
spindle oil and assemble over rotor.
NOTE: Air inlet slots in end of cylinder must be aligned
with two air inlet holes in end plate (8).
• Assemble bearing (13) to end plate (12), pressing on
outer race of bearing.
• Assemble end plate (12) to rotor, pressing on inner race
of bearing. Be sure rotor turns without binding.
• Insert locating pin (16) into 0.081” diameter blind hole at
bottom of motor cavity in housing.
• Align notches of end plates and cylinder and install motor
into housing, aligning notches with locating pin (16).
• Grease and assemble “O” ring (14) to end plate (12).
• Assemble spacer (15) to motor, with counterbore facing
motor.
• Assemble gearing to tool.
Housing and Disassembly
• Clamp air inlet adapter (2) in a smooth face vise.
• Unthread housing (6) with a strap type wrench.
• Remove diffuser washer (3), exhaust cap (4) and two
fillers (5).
Throttle Assembly
• Install two fillers (5) to exhaust cap (4).
• Assemble exhaust cap (4), diffuser washer (3) and inlet
adapter (2) to housing.
• Clean and replace screen (1) in inlet adapter.
Product Parts Information
CAUTION
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased motor
performance, and increased maintenance, and may invalidate all warranties.
Ingersoll Rand is not responsible for customer modification of motors for applications on which Ingersoll Rand was not
consulted.
Repairs should be made only by authorized trained personnel. Consult your nearest Ingersoll Rand Authorized Service
center.
Manuals can be downloaded from www.irtools.com
Refer all communications to the nearest Ingersoll Rand Office or Distributor.

Notes

Notes

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© 2006 Ingersoll Rand Company