ARO GV08A-03S-7 User manual

SECTION
MANUAL
Ml0
174
I
Tool & Hoist Products
INCLUDING: OPERATION,INSTALLATION& MAlNTENANCE Released:
4-30-94
Revised:
4-30-94
MODELS GV08A-03S-7, GV08A-05S-7,
and GV08A-06S-7 SANDERS
MODEL GV08A-02P-7 POLISHER
IMPORTANT SAFETY INFORMATION ENCLOSED.
READ THIS MANUAL BEFORE OPERATING TOOL.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
.
Always operate, inspect and maintain this tool in
accordance with American National Standards
Institute Safety Code for Portable Air Tools .
(ANSI Bl86.1).
. For safety,top performance, and maximum .
durability of parts, operate this tool at 90 psig
(6.2 bar/620 kPa) maximum air pressureat the
inlet with 3/8” (10mm) inside diameter air supply .
hose.
. Air powered tools can vibrate in use. Vibration, .
repetitive motions or uncomfortable positions may
beharmful to your hands and arms. Stop using .
any tool if discomfort, tingling feeling or pain
occurs. Seekmedical advice before resuming use. .
. Always turn off the air supply and disconnect the
air supply hosebefore installing, removing or .
adjusting any accessoryon this tool, or before
performing any maintenance on this tool.
Keep hands, looseclothing and long hair away
from rotating end of tool.
Anticipate and bealert for sudden changesin
motion during start up and operation of any power
tool.
Check for excessivespeedand vibration before
operating.
Tool accessorymay continue to rotate briefly after
throttle is released.
Do not lubricate tools with flammable or volatile
liquids such askerosene,diesel or jet fuel.
Do not remove any labels. Replaceany damaged
label.
Useaccessoriesrecommended by ARO Tool.
The useof other than genuine ARO Tool replacement parts may result in safety hazards, decreasedtool performance,
and increased maintenance, and may invalidate all warranties.
ARO Tool is not responsible for customer modification of tools for applications on which ARO Tool was not consulted.
Repairs should bemadeonly by authorized trained personnel. Consult your nearestARO Tool Authorized Servicenter.
It is the responsibility of the employer to place the information in this manual into the hands of the operator.
For parts and service information, contact your local ARO distributor, or the Customer Service Dept. of the Ingersoll-Rand Distribution Center,
White House, TN at PH: [phone], FAX: [phone]
AROTool & Hoist Products
Ingersoll-RandCompany
©Ingersoll-Rand Company 1994
Printed in U.S.A.
Part of worldwide Ingersoll-Rand

WARNING LABEL IDENTIFICATION
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
WARNING
Always wear eye protection
when operating or perform-
ing maintenance on this
tool.
r
WARNING
Always turn off the air
supply and disconnect the
air supply hose before
installing, removing or
adjusting any accessory on
this tool, or before perform-
ing any maintenance on this
tool.
I
A WARNING
Do not carry the tool by
the hose.
A WARNING
Always wear hearing
protection when operating
this tool.
A WARNING
Air powered tools can
vibrate In use. Vibration,
repetitive motions or uncom-
fortable 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.
WARNING
Operate at 90 psig
(6.2 bar/620 kPa)
Maximum air pressure.
2
.

SANDER/POLISHER SPECIFIC WARNINGS
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
.
TheseSandersand Polishers will operate at the
free speedspecified on the nameplate if the air
supply line-furnishes 90 psig (6.2 bar/620 kPa) air
pressure at the tool. Operation at higher air
pressure will result in excessivespeed.
l
Useonly a sanding pad, buffing wheel or polishing
bonnet with thesetools. Do not useany grinding
wheel, bur or metal removing accessoryother than
a sanding pad with thesetools. Never usean
accessoryhaving a maximum operating speedless
than the free speedof the Sander or Polisher in
which it is being used.
.
When using a pad on a threaded arbor, make
certain the flange nut is tightened securely. Check
the tightness of the flange nut before operating a
Sander or Polisher to make certain it will not
loosenduring operation.
. Before installing a new Motor Housing Assembly,
always selectthe correct Assembly for the motor
packageyou are installing.
PLACING TOOL IN SERVICE
LUBRICATION
IRAX No. 10 IRAX No.28
Always useanair line lubricator with thesetools.
Werecommendthefollowing Filter-Lubricator-Regulator
Unit:
For USA - IRAX No. C11-03-G00
For International - IRAX No. C16-C3-A29
After eacheight hours of operation, replenishtheoil
supply. Adequatelubrication is imperarive for satisfactory
tool life.
After each50 000cyclesor eachmonth, whichever
occurs first, inject approximately 6 ccof IRAX No. 28
Greaseinto theGreaseFitting (41).
INSTALLATION
Air Supply and Connections
Always usecleandry air at 90 psig. maximum air
pressure.Dust,corrosive fumesand/orexcessivemoisture
canruin themotor of anair tool. An air line filter can
greatly increasethelife of anair tool. The filter removes
dustandmoisture.
Besureall hosesandfittings arethecorrectsizeandare
tightly secured.SeeDwg. TPD905-1 for atypical piping
AIR TOOL INLET SIZE
(Dwg. TPD905-1)
GV08A Sanders and Polishers are designedfor standard duty sanding and polishing operations in automobile
repair shops and in sheetmetalfabrication applications.
3

PLACING TOOL IN SERVICE
HOW TO ORDER A SANDER
VERTICAL SANDER WITH LEVER THROTTLE
Model Free Speed,rpm
GV08A-03S-7 3000
Spindle and Back Up Pad
5/8-11, 7”
GV08A-05S-7 5/8-11, 7”
GV08A-06S-7 6 000 5/8-11. 7”
HOW TO ORDER A POLISHER
VERTICAL POLISHER WITH LEVER THROTTLE
Model
GV08A-02P-7
Free Speed,rpm
2400
Spindle and Polishing Bonnet
5/8-l1, 7”
4

MAINTENANCE SECTION

1
*
*
+*
*
2
3
4
5
5A
6
7
8
9
10
11
12
13
14
MotorHousing Assembly ....................
for Model GV08A-02P-7 ............ 49841-101
for Model GV08A-3S-7 ............ 49841-102
for Model GV08A-05S-7 ............ 49841-103
for Model GV08A-06S-7 ............ 49841-104
Decal ................................. 49841-105
WarningLabel .......................... 49843-129
Nameplate
for Model GV08A-02P-7 ............ 49841-106
for Model GV08A-03S-7 ............ 49841-107
for Model GV08A-05S-7 ............ 49841-108
for Model GV08A-06S-7 ............ 49841-109
NameplateScrew(2) ..................... 49843-128
Bearing Nut ............................ 49841-110
RearRotor Bearing ...................... 49841-111
Throttle ValveSeat....................... 49841-112
Throttle Lever .......................... 49841-114
Throttle Lever Pin ....................... 49841-115
Throttle Plunger ......................... 49841-116
Inlet Bushing ........................... 49841-117
Throttle Valve .......................... 49841-118
Throttle Valve Spring ..................... 49841-119
Oiler Body Assembly ..................... 49841-120
Oiler Body Seal ....................... 49460-79
Oiler Plug ............................ 49842-114
Oil ChamberPlug ....................... 49841-121
Oil ChamberPlug Seal ................... 49845-139
* Not illustrated.
+ Whenordering aNameplate,ordernewNameplateScrewsalso.
PART NUMBER FOR ORDERING
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
29A
30
31
PART NUMBER FOR ORDERING
RearEndPlateGasket . . . . . . . . . . . . .. . . . . . . .,. .
RearEndPlate .............................
RearEndPlateRetainer ......................
Rotor for Model GV08A-03S-7 ............
. for all others .......................
VanePacket(setof 4 Vanes) ..................
Cylinder.. ................................
Front EndPlate ............................
Cylinder Dowel ............................
FrontRotor Bearing .........................
FrontRotor BearingHousing .................
FrontRotor BearingRetainer .................
BearingSpringWasher(2) ....................
Bearing Housing Spacer .....................
ExhaustDeflector ..........................
Exhaust Silencer...........................
ExhaustDiffuser ...........................
ExhaustDeflector RearSeal ..................
ExhaustDeflector Front Seal ..................
49841-122
49841-123
19841-124
19841-125
49841-126
49841-127
49841-128
49841-129
49841-130
49841-131
49841-132
49450-28
49460-10
49841-154
$9841-134
19841-135
19841-136
49841-137
49841-138

32
33
34
35
PART NUMBER FOR ORDERING
ArborAssembly
for Model GV08A-06S-7 ............
for Model GV08A-05S-7 ............
for Model GV08A-03S-7 ............
for Model GV08A-2P-7 ............
Arbor for Model GV08A-06S-7 ............
for Model GV08A-05S-7 ............
for Model GV08A-03S-7 ............
for Model GV08A-02P-7 ............
Arbor PlanetGearAssembly(3)
for Model GV08A-06S-7 ............
for Model GV08A-05S-7 ............
for Model GV08A-03S-7 ............
for Model GV08A-02P-7 ............
PlanetGearBearing (1 for eachGear)
for Model GV08A-06S-7 ............
for Model GV08A-05S-7 ............
for Models GV08A-03S-7 and
GV08A-02P-7 .....................
Arbor PlanetGearShaft(3)
for Model GV08A-06S-7 ............
for Model GV08A-05S-7 ............
for Models GV08A-03S-7 and
GV08A-02P-7 .....................
49841-139
49841-140
49841-141
49841-142
49841-143
49841-144
49841-145
49841-146
49460-89
49841-147
49450-98
49841-148
49460-90
49460-86
49450-99
49440-103
49841-149
49841-150
37
38
39
40
41
42
43
44
46
*
*
PART NUMBER FOR ORDERING
Rotor Pinion
for Model GV08A-06S-7 ............
for Model GV08A-05S-7 ............
RearArbor Bearing ......................
Arbor Bearing Spacer ....................
Front Arbor Bearing ......................
GearCaseAssembly ........................
GreaseFitting ...........................
Arbor BearingRetainer ......................
Inner WheelFlange .........................
SandingPadAssembly(firm) .................
WoolBonnet(for Model GV08A-02P-7) ........
Arbor Wrench(15/16”) ......................
SandingPadAssembly(medium) ..............
49841-151
49841-152
49841-153
49841-154
49841-155
49841-156
49440-57
49841-157
49841-158
49845-226 .
49842-141
49841-159
49845-225
* Not illustrated.

MAINTENANCE SECTION
Always wear eyeprotection when operating or
performing maintenance on this tool.
Always turn off the air supply and disconnect the air
supply hosebefore installing, removing or adjusting
any accessoryon this tool, or before performing any
maintenance on this tool.
LUBRICATION
Eachtime aSanderor Polisheris disassembledfor
maintenanceandrepairor replacementof parts.lubricate
thetool asfollows:
1. Workapproximately 1.5cc of IRAX No. 28 Grease
into theRearRotor Bearing (3), Front Rotor
Bearing (23).RearArbor Bearing (37) andFront
Arbor Bearing(39).
2. Workapproximately 4 to 6 ccof IRAX No. 28
Greaseinto thegeartrain. If thegeartrain is
disassembled,greasethePlanetGearBearings(34),
theteethof thePlanetGears(33). theteethof the
Rotor Pinion (36) andthePlanetGearShafts(35).
Work thegreaseinto thegearingif thegeartrain is
not disassembled.Greasetheteethinside theGear
Case(40).
3. Inject 1to 2 ccof IRAX No. 10Oil into theair
inlet beforeattachingtheair hose.RemovetheOil
ChamberPlug andfill theoil chamber.
4. Moisten all O-rings with o-ring lubricant.
DISASSEMBLY
General Instructions
1 Do not disassemblethetool any further than
necessaryto replaceor repair damagedparts.
2. Whenevergraspingatool or apart in avise,always
useleather-coveredor copper-coveredvisejaws to
protectthesurfaceof thepart andhelp prevent
distortion. This is particularly true of threaded
membersandhousings.
3. Do not removeany part which is apresslit in or ona
subassemblyunlesstheremovalof thatpartis
necessaryfor repairsor replacement.
4. Do not disassemblethetool unlessyou havea
completesetof new gasketsandO-rings for
replacements.
Disassembly of the Sander or Polisher
1. SpragtheInner WheelFlange (43) with awrenchand
unscrewandremovetheSandingPadAssembly(44)
andthePadMounting Nut (44).
2. RemovethePadMounting Washers(44) from the
Arbor (32).
3. Carefully graspthehandleof theMotor Housing (1)
in avise with leather-covered or copper-coveredjaws
sothat theArbor is upward.
4. Using awrenchon theflats of theGearCase(40),
loosen,but donot remove.theGearCase.
Becertain to hold the tool over the workbench to
prevent parts from becoming lost.
5. Removethe tool from the vise and.while keeping the
arborin ahorizontal position. unscrewtheGearCase
by handandpull it awayfrom theMotor Housing.
Disassembly of the Gear Case
1.
2.
3.
Threadtwo 5/8-11 jam nutsonto thethreadedendof
theArbor andlock themtogether neartheendof the
Arbor. Grasptheoutermostjam nut in visejaws and,
with anopenendwrench,loosentheInner Wheel
Flange(43).Unlock thetwojam nuts,removethe
Arbor andGearCasefrom thevise andunscrewand
removethetwojam nutsandthe Inner Wheel Flange.
Using snapring pliers, removetheArbor Bearing
Retainer(42) from theGearCase.
Graspingthethreadedendof theArbor, pull the
Arbor, Front Arbor Bearing (39), Arbor Bearing
Spacer(38) andRearArbor Bearing (37) from the
GearCase.
4.
5.
6.
7.
8.
9.
Usingabearingpuller, removetheFront Arbor
Bearingfrom theArbor.
RemovetheArbor Bearing Spacer.
Using abearingpuller, removetheRearArbor
Bearingfrom theArbor.
Pressoneof theArbor PlanetGearShafts(35) from
theArbor andslide theArbor PlanetGear(33) and
Planet GearBearing (34) from theArbor.
For Models GV08A-05S-7 and GV08A-06S-7,
slide theRotor Pinion (36) out of theopening created
by removing thePlanetGear.
Presstheremaining Arbor PlanetGearShaftsfrom
theArbor andremovetheremaining Arbor Planet
GearsandPlanetGearBearings.
10.
11.
12.
Do not remove the PlanetGearBearingsfrom the
Arbor Planet Gearsunlessyou have new Bearings
on hand for replacement. The old Bearings will be
damagedduring the removal process.
PressthePlanetGearBearingsfrom theArbor Planet
Gears.
Pull theExhaustDeflector (28) from the GearCase.
RemovetheExhaustDiffuser (29A) from the Exhaust
Deflectoror thehub of theMotor Housing.
8

MAINTENANCE SECTION
13. RemovetheExhaustDeflector Front Seal(31) from
theGearCase.
14. WorktheExhaustSilencer(29) out of theExhaust
Deflector.
Disassembly of the Motor
1. If theBearing Housing Spacer(27)remainedwith the
assembledmotor,removeit.
2. RemovetheFront Rotor BearingHousing (24) and
thetwo Bearing Spring Washers(26).
3. Graspthesplined endof theRotor andpull the
assembledmotor from theMotor Housing (1).
4. Using apair of external snap-ring pliers with just the
tips of thepliers insertedbetweentheendsof theRear
End PlateRetainer(17) spreadtheRetainerenough
to removeit from thegroovein thehub of theRotor.
Make certain the Retainer doesn’t fly when it is
slipped off the hub of the Rotor.
5. Withdraw theRearEnd Plate(16) Cylinder (20) and
Vanes(19).
6. While supporting theFront End Plate(21) between
two blocks of wood on thetableof anarborpress,
presstheRotor from theFront Rotor Bearing (23).
ChecktheBearing for damageor roughnessby slowly
rotating it.
Do not remove the Rear Rotor Bearing (3) unless
you have a new Bearing on hand for replacement.
The old Bearing will bedamagedduring the
removal process.
7. ToremovetheRearRotor Bearing,threada
No. 10-24 x 2” long capscrew,having atleast l/2” of
thread,through theBearingNut (2) locatedbehind the
Bearing. Keeptightening thescrewtojack the
Bearing from theMotor Housing.
Disassembly of the Throttle
1. Removethe Inlet Bushing (7) andwithdraw theOiler
Body Assembly(10), Throttle ValveSpring (9) and
theThrottle Valve (8).
2. Removethe Throttle Lever Pin (5A), Throttle
Lever (5) andwithdraw theThrottle Plunger (6).
3. Do not removetheThrottle Valve Seat(4) unlessyou
haveanewoneon handfor replacement.The old seat
will bedamagedduring theremovalprocess.To
removetheThrottle Valve Seat,threada3/8-24
threadcapscrewabout3” or 4” long into theSeat;
graspthe headof thecapscrewin a vise,andpull the
Seatfrom thehandle.
ASSEMBLY
General Instructions
1 Always presson theinner ring of aball-type bearing
wheninstalling thebearingona shaft.
2. Always presson theouter ring of aball-type bearing
whenpressingthebearinginto abearingrecess.
3 Whenevergraspinga tool or part in a vise. always use
leather-coveredor copper-coveredvisejaws. Take
extracarenot to damagethreadsor distort housings.
4. Always cleaneverypart andwipe everypart with a
thin film of oil beforeinstallation.
5. Checkeverybearingfor roughness.If anopenbearing
mustbecleaned,washit thoroughly in aclean,
suitable,cleaning solution anddry with acleancloth.
Sealedor shielded bearings should not be cleaned.
Workgreaseinto every openbearingbefore
installation.
6. Apply afilm of o-ring lubricant to every O-ring
beforeinstallation.
7. Unlessotherwisenoted,alwayspresson the stamped
endof aneedlebearingwhen installing a needle
bearinginto arecess.Useabearing inserting tool
similar to theoneshownin Dwg. TPD786.
Needle Bearing Inserting Tool
SHOULDER TO
REGULATE DEPTH PILOT TO FIT I.D. OF
LENGTH OF PILOT TO BE
APPROXIMATELY 1/8”
LESS THAN LENGTH OF
BEARING
(Dwg. TPD786)
9

MAINTENANCE SECTION
Assembly of the Throttle
1. Graspthehandleof theMotor Housing (1) in
copper-coveredvisejaws, positioning thehandleso
that theinlet endis upward.
Never install a usedThrottle Valve Seat;always
install a new one.
2.
3.
4.
5.
6.
7.
If theThrottle Valve Seat(4) wasremoved,usea
flat-faced rod l/2” (13 mm) in diameterandabout
6” (150mm) long topressanewThrottle ValveSeat
into thehandleuntil it seats.
While looking down through theboreof theThrottle
ValveSeat,inserttheThrottle Plunger (6) until the
hole in thePlungeris centeredbeneaththehole in the
Throttle ValveSeat.Install Throttle Lever (5) by
aligning hole in theThrottle Lever with holesin
Motor Housing (1) andinserting Throttle Lever Pin
(5A).
Insert theThrottle Valve(8) sothat thelong-stem end
passesthrough thehole in theThrottle Plunger.
Insert theThrottle Valve Spring (9), smallcoil first, so
that thespringencirclestheThrottle Valve.
Make certain thetwo Oiler Body Seals(11)are
positioned in theannular grooveson theOiler
Body (10) andinstall theOiler Body,counterbored
endfirst, into thehandle.The largeendof the
Throttle ValveSpring should seatin thecounterbore
in theOiler Body.
Threadthe Inlet Bushing (7) into thebottomof the
handleandtighten it to aminimum 25 ft-lb
(33.9Nm) torque.
8. RemovetheMotor Housing from thevise.
Assembly of the Motor
1. If theRearRotor Bearing (3) wasremoved,install a
new oneasfollows:
a. PlacetheBearingNut (2) in theboreatthebottom
of thebearingrecessin theMotor Housing (1).
b. Using abearinginserting tool (seeDrawing
TPD786) thathasapilot extending into the
Bearing,andashoulderthat contactstheouter
radius on thebearingshell, presstheRearRotor
Bearing, unstampedendfirst, into thebearing
recess until it is about.010” (0.25mm)below
flush.
c. Inject alittle greasein theBearing.
2. Slide theFront EndPlate(21), flat sidefirst, over the
splined endof theRotor (18).
3. Using asleevethat contactsonly theinner ring of the
Front Rotor Bearing (23),presstheFront Rotor
Bearing onto thesplinedhub of theRotor until it seats
againsttheFront EndPlate.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
The clearance betweenthe Front End Plate and the
Rotor is critical.
While holding theFront EndPlate,gently tapthe
splinedendof theRotor until you caninsert a0.001”
feelergaugeor shim betweenthe faceof theRotor
andEndPlate.
Graspthesplined endof theRotor in copper-covered
visejaws sothat theshorthub of theRotor is upward.
WipeeachVane(19) with afilm of therecommended
oil andplaceaVanein eachslot in theRotor.
PlacetheCylinder (20). air port endtrailing, down
over theRotor andagainsttheFront EndPlate.
PlacetheRearEnd Plate(16), flat sidefirst, over the
shorthub of theRotor.
Install theRearEnd PlateRetainer(17) in thegroove
on therotor hub.
When installing the Rear End Plate Retainer (17),
make certain it doesnot fly asyou slip it on the
huh of the Rotor.
Smearafilm of therecommendedgreaseon theRear
EndPlateGasket(15) andplace the Gasketon the
EndPlateso that theport in theGasketis aligned
with theport in theEndPlate.
Using anassemblydowel 3/32” in diameterx 10”
long (2.3mmx 254mm), align thedowel groovein
theFront End Plate,Cylinder, RearEnd Plateand
Gasket.Placetheassemblyrod in thealigned grooves
sothatabout3” of therod extendsbeyond theRear
EndPlate.Inserttheextensionin thedowel hole at
thebottomof thehousingbore,andslide the motor
into theMotor Housing until it seats.
Withdraw theassemblydowel andinsert theCylinder
Dowel (22).
Placethetwo Bearing Spring Washers(26) inside the
Front Rotor BearingHousing (24) andagainstthe
Front Rotor BearingRetainer (25).
Slide theFront Rotor Bearing Housing over theFront
Rotor Bearing.
Install theExhaustDeflector RearSeal(30) on the
Motor Housing.
Install theExhaustDiffuser (29A) on thehub of the
Motor Housing.
10

MAINTENANCE SECTION
Assembly of the Gear
l.If thePlanetGearBearings(34) wereremoved,press 12. Using snapring pliers, install the Arbor Bearing
Retainer(42) in the front endof theGearCase.
13. ThreadtheInner WheelFlange (43) onto theArbor.
2.
3.
4.
thenew Bearingsinto theArbor PlanetGears(33)
using abearinginserting tool (seedrawing TPD786)
thathasapilot andthatcontactstheouterradius of
theBearings.Pressagainstthestampedendof the
Bearing.
Smearsomeof therecommendedgreaseon the
Bearingsandteethof thePlanetGears.
Using blocks or aring on thetableof anarborpress,
placethelargeshoulderof theArbor (32), threaded
enddown, on theblocks or thering.
Position oneof theassembledArbor PlanetGearsin
oneof themachinedArbor openings,carefully
aligning thecenterof theGearwith thehole in the
shoulderof theArbor, andpressoneof theArbor
PlanetGearShafts(35) into the Arbor andthrough the
Gear.Make certainboth endsof the Shaftarebelow
thefacesof theArbor.
5.
6.
7.
Repeattheprevious stepwith thesecondPlanetGear.
For Models GV08A-05S-7 and GV08A-06S-7,
greasetheteethof theRotor Pinion (36)andinsertit
into thecenterof theArbor through theremaining
machinedopening. Make certain theteethof the
Rotor Pinion meshwith the teethof thePlanetGears.
Install theremaining Arbor PlanetGearmaking
certainall gearingmeshesandmovesfreely.
8.
9.
10.
11.
Do not pressagainst the Rear Arbor Bearing.
PresstheRearArbor Bearing (37) onto theshaftat
theunthreadedendof theArbor.
Reposition theArbor on thepressingtablewith the
threadedendup.
Position theArbor Bearing Spacer(38)on the Arbor
andpresstheFront Arbor Bearing (39), shieldedside
up, onto theArbor.
Smearsomegreaseon theinternal spline of theGear
Case(40) andinsert theassembledArbor, gearingend
first, into theunsplinedendof theGearCase.Make
certain theteethof thePlanetGearsmeshwith the
teethin theGearCase.
14.
15.
16.
Using two 5/8-11 jam nutson theendof the Arbor,
tighten theInner WheelFlange.
Lubricate andinstall theExhaustDeflector Front
Seal(31)in theannular grooveof theGearCase.
Being carefulnot to cut theSeal,slide the smaller end
of theExhaustDeflector (28) onto theGearCaseuntil
it buttsagainsttheshoulderof theGearCase.
If theExhaustSilencer (29) wasremoved,fold the
Silencerin half lengthwise andwork it into theopen
areabetweentheExhaust Deflector and the Gear
Case.
Assembly of the Tool
1.
2.
3.
4.
5.
6.
Graspingthehandleof theMotor Housing in
copper-coveredor leather-covered visejaws with the
splineof theRotor upward,placetheBearing
Housing Spacer(27) on thefaceof theFront Rotor
BearingHousing.
Position theGearCaseandExhaustDeflector over
theMotor Housing andwhile slowly rotating the
Arbor to align thePlanetGearswith thespline of the
Rotor, screwtheGearCaseonto theMotor Housing.
MakecertaintheExhaustDeflector RearSealis not
cut while threadingtheGearCaseonto theMotor
Housing.
With atorquewrenchon theflats on theGearCase,
tighten theGearCaseto between50 to 60 ft-lb (67.8
to 81.4Nm) torque.
Install thePadMounting Spacers(44) on theArbor.
ThreadtheSandingPad(46) andthePadMounting
nut onto theArbor.
Spin theSandingPadby handto makecertain nothing
is binding, thenremovethetool from the vise.
11

MAINTENANCE SECTION
TROUBLESHOOTING GUIDE
Trouble Probable Cause
Low power or low freespeed
Roughoperation
Scoring
Air leaks
or brokenVanes
..
Wornor brokenCylinder
build-up in themotor
Wornor brokenRearRotor
Bearingor Front Rotor Bearing
BentArbor
Improperassembly
WornValveThrottle and/or
Throttle ValveSeat
Oil ChamberPlug worn or not
tight
Solution
Checktheair pressureat theInlet. The pressure
mustnot exceed90psig (6.2bar/620kPa).
CleantheScreenin aclean,suitable,cleaning
solution. If it cannotbecleaned,replaceit.
Never operate a Sander or Polisher without an
Inlet Screen. Ingestion of dirt into the Sander
or Polisher can, in somecases,causean unsafe
condition.
Replacethecomplete setof Vanes.
ReplacetheCylinder if it is worn or broken or if
theboreis scoredor wavy.
Lubricate theSanderor Polisher asinstructed in
LUBRICATION. If lubrication doesnot result in
satisfactoryoperation,disassemblethe motor,
inspectandcleanall parts.
ExamineeachBearing.ReplacetheRearRotor
BearingSealAssemblyif worn or damagedor
replacetheFront Rotor Bearing.
Mount theArbor on centers.Checkthebearing
diameterrunout with anindicator. Replacethe
Arbor if runout exceeds.002” Total Indicator
Reading.
Make certainthatall motorpartsareproperly
alignedprior to clamping themotorassembly.
Replaceworn parts.
Tighten thePlug. If theproblempersists,replace
it.
SAVE THESE INSTRUCTIONS. DO NOT DESTROY.
Part of worldwide Ingersoll-Rand
PN49999-457
03540481