background image

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 flush 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 identification 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 first. 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 first, 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 flat 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.

Summary of Contents for G2E

Page 1: ...04581245 Edition 2 May 2014 Save These Instructions Air Grinder Die Grinder and Sander Series G2 Angle Maintenance Information ...

Page 2: ...e Collet 77 upward Using the Collet Body Wrench 89 on the flats 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 ...

Page 3: ...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 Diffuser 5 and remove the Lever Assembly 9 Remove the Rear Exhaust Diffuser from the Housing Remove Rear Exhaust Diffuser Gasket 8 Rear Exhaust Diffuser Muffler 10 and Lever Support 6 from the Diffuser If the Ball Valve Seat 16 must be r...

Page 4: ...ft lb 19 0 and 25 8 Nm torque 7 Inject approximately 0 7 cm3 of Ingersoll Rand No 68 Grease into 8 9 1 2 3 4 5 6 7 8 9 1 2 3 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 film of oil and insert Vane into each vane slot in the Rotor Be sure that logo on Vane faces to the left inside the v...

Page 5: ...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 first Saturate the Wick with approximately 1 5 cm3 of Ingersoll Rand No 63 Oil Do not substitut...

Page 6: ...ing 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 Fr...

Page 7: ...e 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 re...

Page 8: ...ingersollrandproducts com 2014 Ingersoll Rand ...

Reviews: