Product Safety Information
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 a Series 88S Sander 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 Sander is used in an extremely dirty environment, once in
each week or after each forty hours of operation, pour a liberal
amount of a suitable cleaning solution into the slots in the handle.
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2.
Work the throttle lever vigorously to wash the cleaning solution
around, 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 Sander 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 with the Spindle upward.
Remove the Cylinder Case Screws (45), the Lock Washers (44), the
Motor Retaining Plate (43), Cylinder Case Gasket (42) and the two
Motor Clamp Washers (41).
Remove the Sander from the vise.
Grasp the Arbor (27) in leather-covered or copper-covered vise
jaws. Lift o the Cylinder Case to expose the motor.
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 Retaining Ring (40) and unscrew the
Controller Assembly which has a left-hand thread that requires a
clockwise rotation for removal.
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6. Lift o the Rotor Bearing Seal (37) 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 Front End Plate (29) in one hand and tap the small diameter
end of the Arbor (27) 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.
13. Place the Cylinder Case in leather-covered or copper-covered
vise jaws 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.
14. Drive out the Throttle Lever Pin (13) to release the Lever
Assembly (14).
15. 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).
16. 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.
17. 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.
18. The Air Strainer Screen (8) can now be removed and cleaned.
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 leather-
covered or copper-covered vise jaws. Take extra care not to
damage threads or distort housings.
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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.
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Lubrication
