Ingersol Rand G1 Series Setup guide

80234313
Edition 2
May 2014
Save These Instructions
Air Grinder, Die Grinder,
Sander and Belt Sander
Series G1 (Angle)
Maintenance Information

2 80234313_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).
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Whenever one of these Grinder, Die Grinder, Sander or Belt
Sander is disassembled for overhaul or replacement of parts,
lubricate the tool as follows::
Always wipe the Vanes (30) with a light lm of oil before inserting
them into the vane slots.
Inject 0.5 to 1.0 cm3 of Ingersoll Rand No. 10 Oil into the air Inlet
Assembly (1) after assembly.
1.
2.
Whenever a new Wick (45) is installed, soak the Wick in
approximately 1-1/2 cm3 of Ingersoll Rand No. 63 Oil. Do not
substitute any other oil.
Whenever the motor is disassembled, remove the old grease and
rell the cavity behind the Rear Rotor Bearing (28) with 3/4 cm3 of
Ingersoll Rand No. 68 Grease.
3.
4.
General Instructions
Do not disassemble the tool any further than necessary to replace
or repair damaged parts.
When grasping a tool or part in a vise, always use soft-sided vise
jaws to protect the surface of the part or tool and help prevent
distortion. This is particularly true of threaded members and
housings.
When grasping a tool in a vise, rst place the tool housing in the
provided Clamp Tool (38), then grasp outer surface of Clamp Tool
in the vise to protect the housing from damage.
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.
Do not press any needle bearing from a part unless you have a
new needle bearing on hand for installation. Needle bearings are
always damaged during the removal process.
Press the Idler Wheel Shaft (84) out of the Yoke and Idler Wheel
(82).
The Idler Wheel contains an Idler Wheel Bearing (83) at each end.
Simultaneously press both Bearings out of the Wheel.
Disassembly of the Sanding Arm (Belt Sander Models)
For 18”models, slide the Cover (69) rearward toward the handle
of the Sander until it is free. It may require a light rap on the front
edge of the Cover to disengage it from its locking points.
Using the Guard Clamp Screw Wrench (85), loosen the Guard
Clamp Screw (71) and remove the Guard (70) and assembled
sanding arm from the Angle Housing (40).
Using a screwdriver, remove the two Clevis Mounting Screws (74)
and separate the Clevis (73) from the Guard.
For 12”x 1/2” and 18” x 1/2”models, use a screwdriver, to remove
the two Belt Plate Retaining Screws (77), two Belt Plate Spacers
(78) and the Belt Plate (76).
If the Belt Pad (75) must be replaced, peel the Pad from the side of
the Clevis or Yoke (79) and scrape the surfaces clean.
To separate the Yoke from the Clevis, press the Yoke
Retaining Pin (81) out of the Yoke and Clevis with an
arbor press.
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2.
3.
4.
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7.
8.
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2.
3.
4.
5.
6.
WARNING
Be careful not to allow the compression of the Yoke Spring
(80) to expel the Yoke or Clevis in an unsafe manner when the
pressing plug is withdrawn from the Yoke.
Disassembly of all Angle Heads
For all Collet models, grasp the tool, mounted in the Clamp Tool
(38), in soft-sided vise jaws with the Collet (50) upward. Using the
Collet Body Wrench (61) on the ats of the Collet Arbor (49) and
the second Collet Body Wrench on the Collet Nut (51), unscrew
the Collet Nut and remove the Collet.
For All Wheel models grasp the tool, mounted in the Clamp Tool
(38), in soft-sided vise jaws with the Flange Nut (60) upward.
For models ending in P63 insert the Arbor Wrench (64) into the
end of the Arbor to keep it from turning and using the Flange Nut
Wrench (65), unscrew and remove the Flange Nut.
For models ending in H63, use the Arbor Wrench (61) on the
ats of the Arbor to keep it from turning and using a 1/2”wrench,
unscrew and remove the Flange Nut.
Remove the wheel, Wheel Flange (59) and Flange Spacer (58) from
the Arbor.
Using a 9/64” hex wrench, loosen Guard Adapter Screw (53) and
remove the Guard Adapter Assembly (52) from
Using a 1/8” hex wrench, unscrew and remove the three Guard
Mounting Screws (57), Guard Lock Washers (56) and Wheel Guard
(54).
For all Belt Sander Models, grasp the tool, mounted in the
Clamp Tool (38), in soft-sided vise jaws with the Arbor (66)
upward. Using the Arbor Wrench (61) on the ats of the arbor to
keep it from turning, unscrew the Drive Sleeve (68) and remove
the Spindle Cap (67).
For all Sander models, grasp the tool, mounted in the Clamp
Tool (38), in soft-sided vise jaws with the Arbor (49) facing upward
For All models - Continue Here
10. Using the Arbor Bearing Cap Wrench (62), unscrew and remove
the Arbor Bearing Cap (48). This is a left-hand thread. Rotate the
Cap Wrench clockwise to remove the Cap.
11. Using the Clamp Nut Wrench (63), loosen the Clamp Nut (42) and
pull the Angle Housing Assembly away from the Motor Housing
(12). This is a left-hand thread. Rotate the Nut Wrench clockwise
to loosen the Nut.
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9.
Lubrication
Disassembly

80234313_ed2 3
12. Grasp the Arbor and pull the assembled Arbor out of the Angle
Head. If the Wick (45) needs replacement, pull it out of the Angle
Housing.
13. If the Upper Arbor Bearing (44) needs replacement, support the
Angle Head on the table of an arbor press, bearing end down,
and press the Bearing out of the Angle Head.
14. Grasp the Arbor in soft sided vise jaws with the output end
downward. Using an adjustable wrench, unscrew and remove the
Bevel Gear Nut (46) and lift the Bevel Gear (39) o the Arbor.
15. If the Lower Arbor Bearing (47) must be replaced, use a piece of
tubing to support the Bearing on the table of an arbor press and
press the Arbor from the Bearing.
WARNING
When removing the Clamp Nut in the following procedure, take
all precautions necessary to prevent the Spacer from being
forcefully ejected in a manner or direction that is hazardous.
16. If the Clamp Nut must be removed from the Angle Housing,
insert the blades of two screwdrivers, approximately 180 degrees
apart, under the Clamp Spacer (41) and pry the Spacer o the
Housing.
Disassembly of the Motor
Remove the Flange clamp (37) and front Housing Cap (36) from
the front of the Motor Housing Assembly (12). Remove the Front
Muer (35) if it remains in the Housing.
Grasp the Bevel Pinion (39) and pull the assembled motor out of
the Motor Housing. Remove the two Rear Rotor Bearing Spacers
(27) from the bottom of the Cylinder (18).
Remove the Vanes (30) from the Rotor (29).
Grasp the Rotor in smooth sided vise jaws with the Bevel Pinion
upward. Using a 9/16”wrench on the Pinion, unscrew and remove
the Pinion.
If the Front Rotor Bearing (34) must be replaced, support the Front
End Plate (31) between two blocks on the table of an arbor press.
Place the blocks as close to the body of the Rotor as possible and
press the Rotor from the Bearing and End Plate. Remove the Front
End Plate Spacer (32) from the hub of the Rotor.
If the Rear Rotor Bearing (28) must be replaced, use snap ring
pliers to remove the Rear Rotor Bearing Retainer (26).
Using a bearing puller, pull the Rear Rotor Bearing o the hub of
the Rotor.
1.
2.
3.
4.
5.
6.
7.
Disassembly of the Inlet and Throttle
Using a 3/4” wrench or six point socket, unscrew and remove the
Inlet Assembly (1).
Remove the Inlet Seal (2) and Inlet Screen from the Inlet
Remove the Ball (4) and Ball Valve Spring (3) from the Cylinder
Assembly (18).
Press the Throttle Lever Pin (7) from the Rear Exhaust Diuser (5)
and remove the Lever Assembly (9).
Remove the Rear Exhaust Diuser from the Housing. Remove Rear
Exhaust Diuser Gasket (8), Rear Exhaust Diuser Muer (10) and
Lever Support (6) from the Diuser.
If the Ball Valve Seat must be replaced, insert a hooked tool
through the central opening of the Seat and, catching the
underside of the Seat, pull it from the Housing.
Remove Rear Housing Muer (11) from the Housing.
Push Throttle Pin Assembly (21) out of Housing and remove from
opening in Cylinder.
Remove Throttle Pin O-Ring (22) from Throttle Pin.
Disassembly of Motor Housing and Cylinder
Thread Inlet Bushing into Cylinder and place Cylinder, Inlet end
down, on at hard surface. Grasp Housing and pull down to
separate it from the Cylinder. Remove Inlet from Cylinder and pull
Cylinder out of Housing.
Remove Flow Guide Assembly (23) and Intake Cover Assembly
(24) from Exhaust Seal (16).
Remove Cylinder Plug Assembly (19) and O-ring (20) from
Cylinder Plug.
Remove Intake Cover O-Ring (25) from Intake Cover.
Remove Rear Cylinder O-Ring (15) and then the Exhaust Seal from
the Cylinder.
Remove Front Cylinder O-Ring (17) from the Cylinder.
If the Throttle Bushing needs to be replaced, insert a small hooked
tool into the hole in the bushing and catch the underside. Pull
Bushing from Cylinder.
9. Place large end of Cylinder on at hard surface and slide Housing
(12) over Cylinder assembly. Be sure that hole in top of Housing
lines up with hole in Throttle Bushing. Press down on Housing
until these holes are aligned. when looking down length of Rotor,
with threaded end away.
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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 into a bearing recess.
Whenever grasping a tool or part in a vise, always use soft-sided
vise jaws. Take extra care not to damage threads or distort
housings.
When grasping a tool in a vise, rst place the tool housing in the
provided Clamp Tool (38), then grasp outer surface of Clamp Tool
in the vise to protect the housing from damage.
Except for bearings, always clean every part and wipe every part
with a thin lm of oil before installation.
Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in clean solvent and dry with a clean
cloth. Sealed or shielded bearings should not be cleaned. Work
grease into every open bearing before installation.
Apply a lm of O-Ring lubricant to every O-Ring before
installation.
Unless otherwise noted, always press on the stamped end of a
needle bearing when installing a needle bearing into a recess
Assembly of Motor Housing and Cylinder
If the Throttle Bushing was removed, Properly secure the Cylinder
(18) and press the Throttle Bushing into the hole on the side of
the Cylinder closest to threaded opening.
1.
2.
3.
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5.
6.
7.
8.
1.
Apply O-Ring lubricant to the Front Cylinder O-Ring (17) and
install onto the small end of Cylinder. Slide O-Ring past all inlet
and exhaust slots, into Front O-Ring groove.
Install Exhaust Seal (16) onto small end of Cylinder and move it
all the way down over O-Ring. Line up and seat protrusion on
Exhaust Seal with slot in Cylinder for proper orientation.
Install the Rear Cylinder O-Ring (15) onto small end of Cylinder.
Slide O-Ring into rear O-Ring groove in Cylinder.
Install the Cylinder Plug O-Ring (20) on the Cylinder Plug (19)
and press the plug into the hole in the Cylinder near the Throttle
Bushing.
Install Intake Cover O-Ring (25) in groove on Intake Cover (24).
Assemble Flow Guide onto Cylinder. For rear exhaust insert the
rubber plug on the Flow Guide into the hole in the Exhaust Seal.
For front exhaust, insert the Flow Guide tab into the Exhaust Seal
hole. There is a protrusion on the Exhaust Seal that inserts into
the groove in the top of the Flow Guide. Be sure this protrusion is
inserted in this groove.
Assemble Intake Cover onto Cylinder. There is a tab on the front of
the Intake Cover that inserts into the Exhaust Seal and a tab that
inserts into a hole in the Cylinder for proper alignment.
9. Place large end of Cylinder on at hard surface and slide
Housing (12) over Cylinder assembly. Be sure that hole in top of
Housing lines up with hole in Throttle Bushing. Press down on
Housing until these holes are aligned.
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4 80234313_ed2
Assembly of the Throttle and Inlet
If the Ball Valve Seat was removed, use a 5/8”wooden dowel with
a at end to push the Seat into the Cylinder.
Assemble Throttle Pin O-Ring (20) onto Throttle Pin (21).
Using needle nose pliers, grasp Throttle Pin above O-Ring and
insert into threaded end of Cylinder. Align Pin with holes in
Cylinder and Housing and insert. Release Throttle Pin and push it
the rest of the way into the hole.
Insert the Ball (4) and then the Ball Valve Spring (3) small end rst
into the Cylinder opening.
Assemble Lever Support (6) into Rear Exhaust Diuser (5), the
U shaped side of support inserted rst into front of the Diuser.
Slide tabs into the slots on the Diuser and line up the holes with
the holes in the Diuser.
Assemble Rear Exhaust Diuser Gasket (8) onto Rear Exhaust
Diuser and assemble Diuser onto the Housing Assembly.
Align hole in Lever Assembly (9) with hole in Exhaust Diuser and
press the Throttle Lever Pin (7) through Exhaust Diuser holes.
Push the Inlet Screen closed end leading, into the large end of the
Inlet Assembly (1), until it is past the threads inside of the Inlet.
After lubricating the Inlet Seal (2) with O-Ring lubricant and being
careful not to nick the Seal on the threads of the Inlet, install the
Seal on the Inlet.
Thread the Inlet Assembly into the Cylinder and tighten it
between 20 to 25 ft–lb (27.1 to 33.9 Nm) torque.
Assembly of the Motor
If the Rear Rotor Bearing (28) was removed, stand the Rotor (29)
upright on the table of an arbor press with the threaded end
downward. Place the threaded rotor hub into a hole drilled into
a at, smooth block so that the Rotor rests at on the large rotor
body. Press the Rear Rotor Bearing onto the hub of the Rotor.
Install the Rear Rotor Bearing Retainer (26) in the groove on the
hub of the Rotor.
Install the Front End Plate (31), counterbored end trailing, onto
the threaded hub of the Rotor. Place the Spacer (32) onto the
threaded hub of the Rotor, in the hole of the Front End Plate.
NOTICE
Before performing the next step, be aware that the Front Rotor
Bearing is a ush ground bearing and must be installed in a
specic manner. The end of the Bearing with a stain or hash
marks must be away from the Spacer.
4. Stand the small hub of the Rotor on the table of an arbor press
with the threaded end upward and press the Front Rotor Bearing
(34) onto the hub of the Rotor.
5. Grasp the assembled Rotor in soft-sided vise jaws with the
threaded rotor hub upward.
6. Thread the Bevel Pinion (39) onto the Rotor and using a torque
wrench, tighten the Pinion between 14 and 19 ft-lb (19.0 and 25.8
Nm) torque.
7. Inject approximately 0.7 cm3 of Ingersoll Rand No. 68 Grease into
the small recess at the bottom of the Cylinder. Drop the two Rear
Rotor Bearing Spacers (27) into the bottom of the Cylinder.
8. Wipe each Vane (30) with a light lm of oil and insert Vane into
each vane slot in the Rotor. Be sure that the black line on Vane
faces to the left inside the vane slot when looking down length of
Rotor, with threaded end away.
9. Grasp the Bevel Pinion and insert the assembled Rotor into the
Cylinder.
10. Assemble the Front Muer (35) into the Front Housing Cap (36).
Ensure muer is installed in the Cap and does not get pushed
down into the Motor Housing.
11. Assemble Front Housing Cap onto Motor Housing (12), aligning
notches on Cap with notches in the Cylinder. Place Flange Clamp
(37) in groove in Cap.
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9.
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3.
Assembly of the Angle Head
If the Upper Arbor Bearing (44) was removed and a new Bearing
must be installed, proceed as follows:
Support the machined face of the Angle Head (40) 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.
b. Press a new Upper Arbor Bearing into the bore, until it is ush
with the top of the Angle Housing.
2. If the Lower Arbor Bearing (47) is being installed, it is necessary
to note the identication 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 (49).
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.
3. Slide the Bevel Gear (39), 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 (46).
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 (45) 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 rst. 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 (42), threaded end trailing, onto the
motor end of the Angle Head. Spread the Clamp Spacer (41) 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. Using the Clamp Nut Wrench (63), 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 (48).
12. Insert the assembled Arbor into the Angle Head, bevel gear
end rst, 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. Using the Arbor Bearing Cap Wrench (62), 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 left-hand thread: turn counterclockwise to
1.
a.

80234313_ed2 5
install.
15. Allow assembled components that have Loctite on threads to
cure before running tool.
Assembly Instructions for All Collet Models
Install the Collet (50) into the end of the Arbor.
Using the Collet Body Wrench (61) to hold the Arbor, thread the
Collet Nut (51) onto the Arbor.
Assembly Instructions for All Wheel Models
Position the Wheel Guard (54) against the at face of the Guard
Adapter Assembly (52) and using a 1/8”hex wrench, install the
three Guard Mounting Screws (57) and Lock Washers (56). Tighten
the Screws to 2.5 to 3.0 ft-lb (3.4 to 4.1 Nm) torque.
Position the Guard Adapter Assembly 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 (53) to 6 to
6.5 ft-lb (8.1 to 8.8 Nm) torque.
For Models ending in P63, thread the Flange Spacer (58) onto the
Arbor and using the Arbor Wrench (64) to hold the Arbor, tighten
the Spacer with the second Arbor Wrench (61).
For Models ending in P63, install the Wheel Flange (59), wheel
and Flange Nut (60) on the Arbor. Use the Arbor Wrench (64) to
hold the Arbor while tightening the Flange Nut with the Flange
Nut Wrench (65).
For models ending in H63, install wheel against at face on Arbor
and install the Flange Nut (60).
Assembly Instructions for All Belt Sander Models
Install the Spindle Cap (67) onto the Arbor (66). Hold the Arbor
with the Arbor Wrench (61) and thread the Drive Sleeve (68) onto
the Arbor and tighten.
Assembly of the Sanding Arm (Belt Sander Models)
NOTICE
In the following step, ball bearings used in models
having 1/4” wide belts must have the bearing seal facing
outward.
If the Idler Wheel Bearings (83) were removed, press one Bearing
into the Idler Wheel (82) until it is ush with the edge of the
Wheel. Invert the Wheel. Press the remaining Bearing into the
Wheel until it is ush with the edge of the Wheel.
NOTICE
In the following step, one hole in the Yoke is slightly larger than
the other one. Determining which hole is larger will enable you
to use nger pressure to insert the Shaft through that side of
the Yoke.
2. Position the assembled Idler Wheel between the two ears of the
Yoke (79) and press the Idler Wheel Shaft through the Yoke and
assembled Idler Wheel.
3. For 12”x 1/2” and 18” x 1/2”models, place the Yoke Spring (80)
into the hole in the end of the Clevis (73) and position the
assembled Yoke over the Spring at the end of the Clevis. Make
certain the slots in the Yoke align with the pin hole in the Clevis.
Compress the Spring with the Yoke and press the Yoke Retaining
Pin (81) through the Clevis and Yoke.
For 18” x 1/4” models, place the Yoke Spring (80) inside the end
of the Yoke opposite the Idler Wheel until it stops against the tab.
Position the Clevis (73) to slide into the Yoke making certain the
Spring enters the slot in the end of the Clevis. Make certain the
slot in the Yoke aligns with the pin hole in the Clevis. Compress
the Spring with the Yoke and press the Yoke Retaining Pin (81)
through the Clevis and Yoke.
4. For 12”x 1/2” and 18” x 1/2”models, insert one of the Belt Plate
Retaining Screws (77) through one of the holes in the Belt Plate
(76). Install one of the Belt Plate Spacers (78) on the Screw
and start the Screw into the Clevis at the guard end. Insert the
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remaining Screw into the hole in the Plate at the yoke end and
install the remaining Spacer on that Screw between the Plate and
Clevis. Tighten both Screws hand tight with a screwdriver.
5. If the Belt Pad (75) is being replaced, peel the protective tape o
the Pad and place the adhesive side of the Pad against the side of
the Clevis opposite the Belt Plate.
6. For 12” models, using a screwdriver, attach the Clevis to the
Guard (70) with the two Clevis Mounting Screws (74). Tighten the
Screws between 8 and 10 in–lb. (0.9 and 1.1 Nm) torque.
For 18” models, position the Alignment Block (72) between the
Clevis and the Guard (70) and secure it in position by attaching
the Clevis to the Guard with the two Clevis Mounting Screws
(74). Tighten the Screws between 8 and 10 in–lb. (0.9 and 1.1 Nm)
torque.
7. Position the Guard on the Angle Head (40) and secure it by
tightening the Guard Clamp Screw (71) between 2 and 3 ft–lb (2.7
and 4.0 Nm) torque.
8. Install a new sanding belt over the Spindle Cap and around the
Idler Wheel.
9. For 18” models, align the Cover (69) with the Guard and slide it
forward toward the Idler Wheel until it snaps into position and
stays there.
10. Operate ths Sander at low speed to determine if the new belt
is tracking properly. If the belt fails to track properly, realign
the Clevis by tightening or loosening one or both of the Clevis
Mounting Screws.

6 80234313_ed2
Trouble Probable Cause Solution
Low power or low free speed Insucient air pressure. Check air line pressure at the Inlet of the Tool. It
must be 90 psig (6.2 bar/620 kPa).
Plugged Inlet Bushing Screen Disassemble the Inlet and remove Exhaust Diuser to
replace Muers for Rear Exhaust. Disassemble Front
Clamp Nut and remove Front Cap for Front Exhaust. Ensure
muer is in Front Cap and not pushed down into Motor
Housing.
Plugged Inlet Screen. Clean the Inlet Screen with a clean, suitable cleaning
solution or replace the Screen.
Worn or broken Vanes. Install a complete set of new Vanes.
Loose Clamp Nut or Arbor Housing. 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.
Cylinder Plug missing, missing O-Ring or out
of hole in Cylinder.
Conrm Cylinder Plug has O-ring and is fully pressed into
Cylinder.
Excessive runout Bent Arbor. Replace the Arbor.
Loose Collet Nut. Tighten the Collet Nut until snug.
Worn or damaged Collet, Collet Nut or
Nosepiece.
Replace the damaged component and retest.
Worn or damaged Upper Arbor Bearing or
Lower Arbor Bearing.
Replace the worn or damaged Bearing.
Scoring of End Plate Worn Front End Plate Spacer or Front End
Plate.
Install a new Front End Plate Spacer and Front End Plate.
Worn Front Rotor Bearing. Install a new Front Rotor Bearing.
Leaky Throttle Valve Dirt accumulation on Throttle Valve or
Throttle Valve Seat.
Disassemble, inspect and clean parts.
Worn Throttle Valve or Throttle Valve Seat. Replace the Throttle Valve and/or Throttle Valve Seat.
Excessive dirt build-up beneath the Throttle
Lever.
Clean out the slot area.
Bent Throttle Valve Plunger. Replace the Plunger.
Exhausts at wrong direction Incorrect orientation of the Flow Guide. Reverse the Flow Guide inside the Motor Housing.
Front Rotor Bearing runs hot Front End Plate Spacer rubbing the bore of
the Front End Plate.
Replace the Front End Plate and Front End Plate Spacer
combination.
Incorrect Front Rotor Bearing installation
orientation.
If a black stain or black hashmarks are not visible on the
face of the Bearing when it is assembled with the End Plate
and Rotor, the Bearing is installed backwards. If possible,
remove the Bearing and install it correctly or replace the
Bearing.
Slow tool idle Bent or leaky Throttle Valve. Replace the Throttle Valve.
Rough operation/vibration Improper lubrication or dirt buildup. Disassemble the Tool and clean in a suitable 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 rear end plate is damaged, replace the Rotor.
Worn or broken Upper Arbor Bearing or
Lower Arbor Bearing.
Replace the worn or broken Bearing.
Worn or broken Bevel Gear or Bevel Pinion. Examine the Bevel Gear and Bevel Pinion. If either is worn
or damaged, replace both the Gear and the Pinion because
they are a matched set and must not be used separately.

80234313_ed2 7
Trouble Probable Cause Solution
Sanding Belt not tracking Worn Idler parts Install a new Idler Wheel Assembly
Misalignment Adjust the Clevis Mounting Screws
Sanding on push side of Clevis Sand on pull side of the Clevis.
Related Documentation
For additional information refer to:
Air Grinder Product Safety Information Form 04584959.
Air Die Grinder Safety Information Form 04580288.
Air Sander Safety Information Form 04580387.
Air Belt Sander Safety Information Form 04584942.
Product Information Manual Forms 80156425 or 80156474 or 80156441 or 80156433.
Parts Information Manual Form 80156458.
Manuals can be downloaded from ingersollrandproducts.com

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