Ingersol Rand 88V Series Setup guide

16573362
Edition 2
February 2014
Save These Instructions
Air Grinder
Series 88V
Maintenance Information

2 16573362_ed2
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
•
•
•
•
•
Whenever a Series 88V Grinder is disassembled for overhaul or
replacement of parts, lubricate as follows:
Inject about 1.5 cc of Ingersoll Rand No. 50 Oil into the Inlet
Bushing (4) after assembly.
If the Grinder is used in an extremely dirty environment, once
each week or after each forty hours of operation, pour a
liberal amount of a suitable cleaning solution into the slots in the
1.
2.
handle. Work the throttle lever vigorously to wash the cleaning
solution around, and then pour the solution and accumulated dirt
from the handle. Repeat this process until the cleaning solution
is clean when it comes out of the handle. Immediately after
ushing with the cleaning solution, inject a liberal amount of
Ingersoll Rand No. 50 Oil in the slots and, again, work the throttle
lever vigorously to lubricate the cleaned parts.
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 t 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 Motor and Throttle
Grasp the ats of the live air handle in leather-covered or copper-
covered vise jaws, Guard up.
Remove the Cylinder Case Screws (46), the Lock Washers (45),
the Guard, Cylinder Case Gasket (42) and two Motor Clamp
Washers (41).
Remove the Grinder from the vise.
Grasp the Arbor (27) in the vise. Lift o the Cylinder Case to
expose the motor.
NOTICE
Use only the special No. 88V60-950 Controller Wrench for
removing the Controller Assembly (39). Do not attempt to
disassemble the Controller. It is available only as a unit and is
guaranteed for the life of the tool if it is not abused.
5. Remove the Controller Ring (40) and unscrew the Controller
Assembly which has a left-hand thread that requires a clockwise
rotation for removal.
1.
2.
3.
4.
1.
2.
3.
4.
6. Lift o the Rotor Bearing Seal (38) and the Rear End Plate (35).
7. Lift o the Cylinder (33).
8. Remove the Vanes (32).
9. Withdraw the Rotor (31) and lift out the Rotor Key (30).
10. Remove the arbor and end plate assembly from the vise. Grasp
the End Plate (29) in one hand and tap the small diameter end of
the arbor with a soft hammer to remove the End Plate.
11. If the Front Rotor Bearing (28) is to be replaced, press it from the
arbor.
12. Insert the Controller into the No. 99V60-A952 Bearing Clamp
and tighten the nut on the xture. Insert the No. 99V60-951
Seal Pressing Tool in the center and press o the Controller.
Release the clamp.
Dissasembly of the Throttle and Inlet
Place the Cylinder Case in the vise to remove the Inlet
Bushing (4), Inlet Bushing Screen (5) and the Throttle Valve
Spring (6). The Bushing has an interference thread and is tightly
t.
Drive out the Throttle Lever Pin (13) to release the Lever
Assembly (14).
Using a 3/32” hex wrench, reach inside the handle and remove
the Valve Seat Screw (12) from the Throttle Valve Seat Support
Assembly (7).
Thread a No. 8-32 screw about 5” (127 mm) long into the throttle
valve seat support in place of the removed valve seat screw. A
piece of 5/32” welding rod can be threaded on one end to serve
the same purpose.
Grasp the protruding end of the screw in a vise, and while tapping
lightly on the housing or handle with a plastic hammer, pull on
the housing or handle to withdraw the throttle parts.
The Air Strainer Screen (8) can now be removed and cleaned.
1.
2.
3.
4.
5.
6.
Assembly
General 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 in a bearing recess.
Whenever grasping a tool or part in a vise, always use
leather-covered or copper-covered vise jaws. Take extra care not
to damage threads or distort 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.
Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in a clean, suitable cleaning solution
and dry with a clean cloth. Sealed or shielded bearing should
never be cleaned. Work grease thoroughly into every open
bearing before installation.
4.
5.
6.

16573362_ed2 3
Assembly of the Throttle and Inlet
NOTICE
Thoroughly clean and lubricate all Throttle Valve
components before assembling the tool. Lubricate with
Ingersoll Rand No. 10 Oil.
Grasp the Dead Handle in leather-covered or copper-covered vise
jaws with the live air handle upward.
Assemble the valve seat support parts.
Insert the Support Assembly (7) into the handle, large diameter
rst. Locate a punch on the at of the screw head and tap it with a
hammer until the Assembly is rmly seated.
Apply O-ring lubricant to the Seals (3). Fit the seals to the Throttle
Valve (2) and push the assembly, small diameter rst, into the
handle until it seats rmly.
NOTICE
If Lever Assembly being serviced does not have the window-type
lever, install a complete new Lever Assembly.
5. Assemble the Lever Assembly (14) as illustrated below.
Locking Lever Assembly
(Dwg. TPD563)
6. Align the holes in the Lever Assembly with the slots in the
Cylinder Case. With a soft face hammer, tap the Throttle Lever
Pin (13) through the Lever Assembly. File o any sharp edges.
Operate the mechanism internally by hand to assure operation.
7. Insert Throttle Valve Spring (6), small end rst.
8. Clean the face of the Inlet Bushing (4) and the Inlet Bushing
Screen (5) using a clean, suitable, cleaning solution, and dry
them. Insert the Screen and Bushing in the end of the Cylinder
Case by grasping the ats with a wrench. Tighten to 35 to 45 ft-lb
(47 to 61 Nm) torque.
Assembly of the Motor
Using an arbor press against the inner race of the bearing, install
the Front Rotor Bearing (28) onto the Arbor (27).
Inspect the Front End Plate (29) for nicks or burrs. If replacement
is necessary, wipe the part with oil. Press the Arbor Bearing into
the Front End Plate.
Hold the Arbor in leather-covered or copper-covered vise jaws.
Insert the Rotor Key (30) in the slot of the Rotor (31). The Rotor has
a staked keyway on one end. Place that end up, over the Arbor.
Apply a light lm of the recommended oil to each Vane (32) and
insert one vane, straight edge out, into each slot in the Rotor. If
any new vanes are required, replace the entire set.
Place the Cylinder over the Rotor matching the Cylinder
Dowel hole to the alignment hole in the Front End Plate (29), with
the kidney port to the right of the dowel hole.
Apply the Rear End Plate (35) with the kidney port to the right of
the dowel hole.
1.
2.
3.
4.
1.
2.
3.
4.
5.
NOTICE
Take all measurements 30 degrees to the left of the dowel hole
when facing the hub side of the Seal. Install the Rotor Bearing
Seal hub down.
NOTICE
Prior to tool assembly, carefully inspect the Controller Assembly
for nicks, gouges or dents. Replace it with a new Controller
Assembly if necessary. Test free speed before applying a
grinding wheel.
NOTICE
If the Controller Assembly (37) needs to be replaced, you must also
replace the Rotor Bearing Seal Assembly (38) which consists of a
rear rotor bearing and a rotor bearing seal. If either the rear rotor
bearing or rotor bearing seal needs to be replaced, BOTH must be
replaced with a new bearing and seal. Do not mix old and new parts.
6. Check the outside diameter and large inside diameter of the
Rotor Bearing Seal (38) for wear. If the outside diameter is worn to
1.1764” (29.881 mm) or smaller, and/or the large inside diameter
is worn to 0.9103”(23.122 mm) or larger, install a new Rotor
Bearing Seal.
7. Align the Rear End Plate (35), cavity and pin up, with the larger
hole in the Rotor Bearing Seal.
8. Press the Rotor Bearing Seal Assembly onto the hub of the
Controller.
9. Slip the Controller Assembly over the arbor. Rotate the Controller
counterclockwise since this is a left-hand thread.
NOTICE
Use only the special No. 88V60-950 Controller Wrench for
applying the assembly.
WARNING
Tighten the Controller to 14 to 16 ft-lb (19.0 to 21.7 Nm) torque.
Do not exceed 16 ft-lb. The Controller may be damaged if this
torque is exceeded.
Always check the free speed of a Grinder after it has been
reassembled and before it is put back into service. Refer to the
Test and Inspection Procedure.
Never use a Grinder which runs in excess of the maximum speed
listed in the Test and Inspection Procedure.
10. Install the Controller Retaining Ring (40), concave face closest to
the Controller.
11. Place the lever handle in leather-covered or copper- covered vise jaws,
open end of the Cylinder Case Assembly up. Lightly dampen the Rear
End Plate Gasket (36) with oil and line it up with the hole in the Cylinder
Case so that the notch in the Gasket matches the Cylinder Case.
12. With an assembly dowel, line up the motor in the Cylinder Case.
Remove the assembly dowel and insert the Cylinder Dowel (34).
13. Install the two Motor Clamp Washers (41) concave or dish side up.
14. Apply the Cylinder Case Gasket (42), the proper Guard (43 or 44),
the Cylinder Case Screw Lock Washers (45) and the ve
Screws (46). Slightly tighten opposite screws, make sure the arbor
is free, then tighten all screws to 14 ft-lb (19 Nm) torque.
15. Again make certain the Arbor is free.
16. The Dead Handle (25) may be adjusted to two positions. Insert
a 5” (127 mm) long 3/16”hex wrench into the elongated slot in
the end of the Dead Handle and loosen the screw securing the
Handle to the Cylinder Case. Rotate the Handle 180oand tighten
the screw to 18 ft-lb (24.4 Nm) torque.

4 16573362_ed2
WARNING
Disconnect the Grinder from the air supply hose or shut o
air to the tool before proceeding with the Test and Inspection
Procedure.
Run the performance tests at 90 psig (6.2 bar/620 kPa) air pressure at
the inlet of the tool with an eight foot (2.44 m) length of 3/4”(19 mm)
diameter air supply hose.
Without a wheel on the tool, operate the Grinder with the Throttle
Lever fully depressed and check the free speed by applying a
hand-held tachometer to the spindle end. The minimum and
maximum allowable free speeds are as follows:
Model Stamped Free Speed, rpm
Min. Max.
88V60
88V77
6000
7700
5650
7250
6050
7750
2. Test the Grinder motor for power to determine these minimum
performance levels. The Throttle Lever must not be actuated
repeatedly during the test. Depress the Lever and hold it in the
open position until the test is complete.
1.
Model Torque Speed rpm
ft-lb Nm
88V60
88V77
88V85
1.89
1.65
1.60
2.6
2.2
2.2
5000
6000
6500
3. There must be no objectionable leaks in any non-exhaust area.
The Throttle must not leak when it is closed.
4. There must be no leaks past the closed Throttle that will run the
motor.
5. The Grinder must start smoothly when the Throttle Lever is
depressed and must shut o completely when the Throttle Lever
is released.
6. The Grinder must be equipped with a spring-loaded window
style Lever Lock (15). The Lever Lock must return to the locked
position when the Throttle Lever is released.
7. The tool must run smoothly without noticeable vibration or
unusual sound.
8. The Arbor (27) must turn freely with no evidence of brinnelled
bearings.
9. The threads on the arbor must be free of nicks and damage.
10. The Nameplate must be legible, in place and securely fastened.
Make replacement if necessary.
Test and Inspection Procedure
Troubleshooting Guide
Trouble Probable Cause Solution
Low power or low free speed Insucient air pressure at the inlet Check air line pressure at the Inlet of the Tool. It must be
90 psig (6.2 bar/620 kPa).
Plugged Screens Clean the Inlet Bushing Screen in a clean, suitable, cleaning
solution. If it cannot be cleaned, replace it.
WARNING
Never operate a Grinder without an Inlet Screen.
Ingestion of dirt into the Grinder can, in some cases,
cause an unsafe condition.
Worn or broken Vanes Install a complete set of new Vanes.
Worn or broken Cylinder Replace the Cylinder if it appears cracked or if the bore is
wavy or scored.
Improper lubrication or dirt build-up in
the motor
Lubricate the Grinder as instructed in LUBRICATION
SPECIFICATION. If lubrication does not result in
satisfactory operation, disassemble the motor, and inspect
and clean all parts.
Rough operation Worn or broken Rear Rotor Bearing or
Front Rotor Bearing
Examine each Bearing. Replace the Rear Rotor Bearing
Seal Assembly if worn or damaged or replace the Front
Rotor Bearing.
Worn Rotor Key Replace the Key. Check the Arbor and Rotor for key slot
wear and replace if necessary.
Bent Arbor Mount the Arbor on centers. Check bearing diameter
runout with an indicator. Replace the Arbor if runout
exceeds 0.002”(0.051 mm) Total Indicator Reading.
Scoring Improper assembly Make certain that all motor parts are properly aligned prior
to clamping the motor assembly.
Rotor Bearing Seal misalignment Loosen the Cylinder Case Screws. Rotate the spindle by
hand to align the seal. Tighten the screws to 14 ft-lb
(19 Nm) torque. Spindle must rotate freely.
Air leaks Worn Valve Seat or Valve Seat Washer Replace worn parts.
Worn Throttle Valve Seals Replace both Seals.
Worn Cylinder Case Gasket between the
Cylinder Case and the Guard
Replace the Gasket.
Distorted face on the Cylinder Polish lightly using ne emery cloth on a at metal plate to
remove high spots. If the tool has been dropped and the
Cylinder Case is damaged, replace it with a new Cylinder
Case Assembly.

16573362_ed2 5
Related Documentation
For additional information refer to:
Product Safety Information Manual 04584959.
Product Information Manual 16573222 and 16576092.
Parts Information Manual 16573305.
Manuals can be downloaded from ingersollrandproducts.com.

Notes:

Notes:

ingersollrandproducts.com
© 2014 Ingersoll Rand