Ingersol Rand 88S Series Setup guide

16574980
Edition 2
May 2014
Save These Instructions
Air Sanders
88S Series
Maintenance Information

2 16574980_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).
•
•
•
•
•
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.
1.
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.
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 Retaining 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 (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.
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.
Lubrication

16574980_ed2 3
Assembly of the Throttle and Inlet
Assemble the Valve Seat Support parts (7, 8, 9, 10, 11 and 12).
Tighten the Valve Seat Screw to 12 in-lb (1.4 Nm) torque.
Insert the assembly into the handle, large diameter rst. Position a
punch against 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.
Assemble the Locking Lever Assembly (14) as illustrated below:
(Dwg. TPD563)
5. 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.
6. Insert the Throttle Valve Spring (6) small end rst.
7. Clean the face of the Inlet Bushing and the Inlet Bushing
Screen (5) with a suitable cleaning solution and allow to air dry.
Insert the parts into the live air handle. Grasping the ats of the
Cylinder Case 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 Front Rotor Bearing
into the Front End Plate.
Hold the Arbor in leather-covered or copper-covered vise jaws.
Insert the Rotor Key (30) into 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 aligning the Cylinder Dowel hole
with the alignment hole in the Front End Plate (29), and 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.
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
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
1.
2.
3.
4.
1.
2.
3.
4.
5.
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 1.176” (29.88 mm) or smaller, and/or the large inside diameter
is worn to 0.910”(23.12 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 Rear Rotor Bearing Seal Assembly onto the hub of the
Controller.
NOTICE
Use only the special 88V60-950 Controller Wrench for installing
the Controller Assembly.
WARNING
Tighten the Controller between 14 and 16 ft-lb (19.0 and 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 Sander after it has been
reassembled and before it is put back into service. Refer to the
Test and Inspection Procedure.
Never use a Sander which runs in excess of the maximum speed
listed in the Test and Inspection Procedure.
9. Thread the Controller Assembly onto the end of the Arbor. Rotate
the Controller clockwise since this is a left-hand thread.
10. Install the Controller Retaining Ring (40) onto the Arbor with the
concave face closest to the Controller.
11. Place the live air handle in leather-covered or copper-covered
vise jaws, Cylinder Case Assembly up. Lightly dampen the Rear
End Plate Gasket (36) with oil. Line the hole in the Gasket with the
hole in the Cylinder Case, and align the notch in the Gasket with
the notch in the motor seat.
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 Motor Retaining
Plate (43), the Cylinder Case Screw Lock Washers (45) and the ve
Screws (46). Slightly tighten opposite screws, make sure the arbor
is free, and tighten all screws to 14 ft-lb (19 Nm) torque.
15. Rotate the Arbor manually to make certain it 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 1805 and tighten
the screw to 18 ft-lb (24.4 Nm) torque.
17. Install the Exhaust Deector (20) and Screws (21).

4 16574980_ed2
Test And Inspection Procedure
WARNING
Disconnect the sander from the air supply hose or shut o air to
the tool and bleed the air from the line 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 length of 3/4”(19 mm)
diameter air supply hose.
Without a sanding pad on the tool, operate the Sander with the
Throttle Lever fully actuated and check the free speed by applying
a hand-held tachometer to the spindle end. Record the Sander
serial number, date of test and actual free speed in a permanent
le. The minimum and maximum allowable free speeds are as
follows:
Model Stamped Free Speed, rpm
Min. Max.
88S45 4500 4300 4550
88S60 6000 5650 6050
1.
2. Attach the power test adapter to the spindle and test the 88S45
using a 4F Test Fan and test the 88S60 using an R3 Fan. The
minimum allowable speed for 88S45 is 3 000 rpm; for 88S60, it is
4 700 rpm.
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 Sander must start smoothly when the Throttle Lever is
actuated and must shut o completely when the Throttle Lever is
released.
6. The Sander must be equipped with a spring-loaded window
style Lock (15). The Lock must return to the locked position when
the Throttle Lever is released and must prevent operation of the
Throttle.
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.
Troubleshooting Guide
Trouble Probable Cause Solution
Low power or low free speed Low air pressure at the Inlet Check the air pressure at the Inlet. The pressure must not exceed
90 psig (6.2 bar/620 kPa).
Plugged Inlet Bushing Screen Clean the Screen in a clean, suitable, cleaning solution. If it
cannot be cleaned, replace it.
WARNING
Never operate a Sander without an Inlet Screen. Ingestion
of dirt into the Sander can, in some cases, cause an unsafe
condition.
Worn or broken Vanes Replace a complete set of Vanes.
Worn or broken Cylinder Replace the Cylinder if it is worn or broken or if the bore is scored
or wavy.
Improper lubrication or dirt build-up in
the motor
Lubricate the Sander 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 the bearing diameter runout
with an indicator. Replace the Arbor if runout exceeds 0.002”
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. Re-tighten the Screws to 14 ft-lb (19 Nm) torque.
The Spindle must rotate freely.
Air leaks Worn Valve Seat or Valve Seat Washer Replace worn parts.
Worn Throttle Valve Seals Replace both Seals.
Related Documentation
For additional information refer to:
Product Safety Information Manual 04580387.
Product Information Manual 80152861 and 80152879.
Parts Information Manual 16573909.
Manuals can be downloaded from ingersollrandproducts.com

Notes

Notes

Notes

ingersollrandproducts.com
© 2014 Ingersoll Rand