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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 off 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
•
•
•
•
•
Each time the Series 77A Grinder, Sander, and Polisher is
disassembled for maintenance, repair or replacement of parts,
lubricate the tool:
Moisten all O-rings with O-ring lubricant.
Coat the inner surface of the Arbor Coupling (42), the spline of the
Rotor (26) and the spline of the Bevel Pinion (31) with 3
to 4 cc of
Ingersoll Rand
No. 68 Grease.
Do not substitute any
other grease.
1.
2.
After assembling the tool, remove the Oil Chamber Plug (7) and
fill the oil chamber with
Ingersoll Rand
No. 50 Oil. Tighten the
Plug to 3-3/4 to 7-1/2 ft-lb (5 to 10 Nm) torque. Inject 2.5 cc of
the recommended oil into the inlet before installing the Inlet
Bushing (4).
Inject 5 cc of
Ingersoll Rand
No. 68 Grease into both Grease
Fittings (44).
3.
4.
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 fit 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.
Disassembly of the Angle Head
For Model 77A60P107, 77A60P109 or 77A75P107:
Grasp the Angle Arbor Housing (43) in leather-covered or copper-
covered vise jaws, angle head up.
Insert a 5” (127 mm) long 3/16” hex wrench into the elongated slot
in the end of the Dead Handle (70) and loosen and remove the
screw and the Dead Handle from the Angle Arbor Housing (43).
Using the Autobalancer Wrench (Part No. 88V60-169) to hold the
Depressed Center Wheel Arbor (60) against rotation, proceed as
follows:
Using a hex wrench, unscrew and remove the Wheel Retaining
Screw (65).
For Type 27 and 28 Plain Hole Wheels,
use the Depressed
Center Wheel Nut Spanner Wrench (Part No. D32-26) to
unscrew and remove the Depressed Center Wheel Nut (67).
Remove the wheel.
For Type 27 and 28 Mounted Wheels,
unscrew the wheel.
For Type 27 and 28 Plain Hole Wheels,
unscrew and remove
the Depressed Center Wheel Flange (66 or 68).
For Type 27 and 28 Mounted Wheels,
remove any Depressed
Center Wheel Spacers (63).
4. Slide the Autobalancer Assembly (61) off the Arbor.
5. Unscrew and remove the Wheel Guard Screws (54). Remove the
Screw Lock Washers (53) and the Wheel Guard (59).
6. Lift the Depressed Center Wheel Arbor (60) from the Angle Arbor
Housing.
1.
2.
3.
4.
1.
2.
3.
a.
b.
c.
WARNING
Do not remove the Mounting Plate Pin (45) unless it is bent or
broken. The Mounting Plate Pin is the alignment pin for the
Wheel Guard and must be used to assure correct mounting of
the Wheel Guard. Use pliers to remove the Mounting Plate Pin if
removal is necessary and a new pin is available.
7. Remove the Angle Arbor Housing from the vise.
8. Lay the Angle Arbor Housing on a workbench, guard side down.
Lightly tap the angle arbor housing head with a soft hammer to
release the Upper Arbor Bearing (47) and Upper Bearing Spring
Washer (46).
NOTICE
A thread locking compound was applied to the threads of the
Bevel Gear Nut (48) during assembly. It may be necessary to
warm the Nut with a propane torch in order to remove it. Use
only enough heat to warm the Nut for removal. Do not overheat.
9. Grasp the flats of the Depressed Center Wheel Arbor in leather-
covered or copper-covered vise jaws, Arbor Bearing end up. Using
a wrench, remove the Bevel Gear Nut.
10. Remove the Bevel Gear Spacer (49) and Bevel Gear (40).
11. Press the Arbor Lower Bearing Assembly (50) from the Arbor.
Remove the Lower Arbor Spring Washer (51). Remove the Arbor
from the vise.
For Model 77A25F107, 77A45W109 or 77A60W107:
Grasp the Angle Arbor Housing (43) in leather-covered or copper-
covered vise jaws, angle head up.
Use a No. DG120-69 Sander Arbor Wrench to hold the Arbor (55).
Remove the Pad Mounting Kit nut (57).
For Model 77A25F107 Polisher,
remove the Wool Bonnet (58).
Unscrew and remove the Sanding Pad Assembly (56).
For Model 77A45W109 or 77A60W107 Sander,
remove the
Sanding Pad Assembly.
Remove the Pad Mounting Kit washers (57).
Unscrew and remove the Retaining Plate Screws (54). Remove the
Screw Lock Washers (53) and the Sander Arbor Retaining Plate (52).
1.
2.
3.
4.
5.
6.
