INGERSOLL RAND 7P24L (01) PDF Document

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 off 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.

Each time a Sander or Polisher is disassembled for maintenance and repair or replacement of parts, lubricate the tool as follows:

1. Work approximately 1.5 cc of Ingersoll Rand No. 28 Grease into the Rear Rotor Bearing (3), Front Rotor Bearing (23), Rear Arbor Bearing (37) and Front Arbor Bearing (39).

2. Work approximately 4 to 6 cc of Ingersoll Rand No. 28 Grease into the gear train. If the gear train is disassembled, grease the Planet Gear Bearings (34), the teeth of the Planet Gears (33), the teeth of the Rotor Pinion (36) and the Planet Gear Shafts (35). Work the grease into the gearing if the gear train is not disassembled. Grease the teeth inside the Gear Case (40).

3. Inject 1 to 2 cc of Ingersoll Rand No. 10 Oil into the air inlet before attaching the air hose. Remove the Oil Chamber Plug and fill the oil chamber.

4. Moisten all O-rings with O-ring lubricant.

1. Do not disassemble the tool any further than necessary to replace or repair damaged parts.

2. Whenever grasping a tool or a 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.

3. Do not remove any part which is a press fit in or on a subassembly unless the removal of that part is necessary for repairs or replacement.

4. Do not disassemble the tool unless you have a complete set of new gaskets and O rings for replacements.

1. Sprag the Inner Wheel Flange (43) with a wrench and unscrew and remove the Sanding Pad Assembly (44) and the Pad Mounting Nut (44).

2. Remove the Pad Mounting Washers (44) from the Arbor (32).

3. Carefully grasp the handle of the Motor Housing (1) in a vise with leather covered or copper covered jaws so that the Arbor is upward.

4. Using a wrench on the flats of the Gear Case (40), loosen, but do not remove, the Gear Case. Be certain to hold the tool over the workbench to prevent parts from becoming lost.

5. Remove the tool from the vise and, while keeping the arbor in a horizontal position, unscrew the Gear Case by hand and pull it away from the Motor Housing.

1. Thread two 5/8-11 jam nuts onto the threaded end of the Arbor and lock them together near the end of the Arbor. Grasp the outermost jam nut in vise jaws and, with an open end wrench, loosen the Inner Wheel Flange (43). Unlock the two jam nuts, remove the Arbor and Gear Case from the vise and unscrew and remove the two jam nuts and the Inner Wheel Flange.

2. Using snap ring pliers, remove the Arbor Bearing Retainer (42) from the Gear Case.

3. Grasping the threaded end of the Arbor, pull the Arbor, Front Arbor Bearing (39), Arbor Bearing Spacer (38) and Rear Arbor Bearing (37) from the Gear Case.

4. Using a bearing puller, remove the Front Arbor Bearing from the Arbor.

5. Remove the Arbor Bearing Spacer.

6. Using a bearing puller, remove the Rear Arbor Bearing from the Arbor.

7. Press one of the Arbor Planet Gear Shafts (35) from the Arbor and slide the Arbor Planet Gear (33) and Planet Gear Bearing (34) from the Arbor.

8. For Models 7S48L, and 7S60L, slide the Rotor Pinion (36) out of the opening created by removing the Planet Gear.

9. Press the remaining Arbor Planet Gear Shafts from the Arbor and remove the remaining Arbor Planet Gears and Planet Gear Bearings.

NOTICE: Do not remove the Planet Gear Bearings from the Arbor Planet Gears unless you have new Bearings on hand for replacement. The old Bearings will be damaged during the removal process.

10. Press the Planet Gear Bearings from the Arbor Planet Gears.

11. Pull the Exhaust Deflector (28) from the Gear Case.

12. Remove the Exhaust Diffuser (29A) from the Exhaust Deflector or the hub of the Motor Housing.

13. Remove the Exhaust Deflector Front Seal (31) from the Gear Case.

14. Work the Exhaust Silencer (29) out of the Exhaust Deflector.

1. If the Bearing Housing Spacer (27) remained with the assembled motor, remove it.

2. Remove the Front Rotor Bearing Housing (24) and the two Bearing Spring Washers (26).

3. Grasp the splined end of the Rotor and pull the assembled motor from the Motor Housing (1).

4. Using a pair of external snap ring pliers with just the tips of the pliers inserted between the ends of the Rear End Plate Retainer (17), spread the Retainer enough to remove it from the groove in the hub of the Rotor.

CAUTION: Make certain the Retainer doesn’t fly when it is slipped off the hub of the Rotor.

5. Withdraw the Rear End Plate (16), Cylinder (20) and Vanes (19).

6. While supporting the Front End Plate (21) between two blocks of wood on the table of an arbor press, press the Rotor from the Front Rotor Bearing (23). Check the Bearing for damage or roughness by slowly rotating it.

NOTICE: Do not remove the Rear Rotor Bearing (3) unless you have a new Bearing on hand for replacement. The old Bearing will be damaged during the removal process.

7. To remove the Rear Rotor Bearing, thread a No. 10-24 x 2″ long cap screw, having at least 1/2″ of thread, through the Bearing Nut (2) located behind the Bearing. Keep tightening the screw to jack the Bearing from the Motor Housing.

1. Remove the Inlet Bushing (7) and withdraw the Valve Spring Spacer (10), Throttle Valve Spring (9) and the Throttle Valve (8).

2. Remove the Throttle Lever Pin (5B), Throttle Lever (5A) and withdraw the Trigger Pin (6).

3. Do not remove the Throttle Valve Seat (4) unless you have a new one on hand for replacement. The old seat will be damaged during the removal process. To remove the Throttle Valve Seat, thread a 3/8-24 thread cap screw about 3″ or 4″ long into the Seat; grasp the head of the cap screw in a vise, and pull the Seat from the handle.

1. Always press on the inner ring of a ball type bearing when installing the bearing on a shaft.

2. Always press on the outer ring of a ball type bearing when pressing the bearing into a bearing recess.

3. 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.

4. Except for bearings, always clean every part and wipe every part with a thin film of oil before installation.

5. Check every bearing for roughness. If an open bearing must be cleaned, wash it thoroughly in clean solution and dry with a clean cloth. Sealed or shielded bearings should not be cleaned. Work grease into every open bearing before installation.

6. Apply a film of O ring lubricant to every O ring before installation.

7. Unless otherwise noted, always press on the stamped end of a needle bearing when installing a needle bearing into a recess. Use a bearing inserting tool similar to the one shown in Dwg. TPD786.

1. Grasp the handle of the Motor Housing (1) in copper covered vise jaws, positioning the handle so that the inlet end is upward.

NOTICE: Never install a used Throttle Valve Seat; always install a new one.

2. If the Throttle Valve Seat (4) was removed, use a flat faced rod 1/2″ (13 mm) in diameter and about 6″ (150 mm) long to press a new Throttle Valve Seat into the handle until it seats.

3. While looking down through the bore of the Throttle Valve Seat, insert the Throttle Plunger (6) until the hole in the Trigger Pin is centered beneath the hole in the Throttle Valve Seat. Install Throttle Lever (5A) by aligning hole in the Throttle Lever with holes in Motor Housing (1) and inserting Throttle Lever Pin (5B).

4. Insert the Throttle Valve (8) so that the long stem end passes through the hole in the Trigger Stem or Trigger Pin.

5. Insert the Throttle Valve Spring (9), small coil first, so that the spring encircles the Throttle Valve.

6. Install the Valve Spring Spacer (10), counterbored end first, into the handle. The large end of the Throttle Valve Spring should seat in the counterbore in the Oiler Body.

7. Thread the Inlet Bushing (7) into the bottom of the handle and tighten it to a minimum 25 ft-lb (33.9 Nm) torque.

8. Remove the Motor Housing from the vise.

1. If the Rear Rotor Bearing (3) was removed, install a new one as follows:

a. Place the Bearing Nut (2) in the bore at the bottom of the bearing recess in the Motor Housing (1).

b. Using a bearing inserting tool (see Drawing TPD786) that has a pilot extending into the Bearing, and a shoulder that contacts the outer radius on the bearing shell, press the Rear Rotor Bearing, unstamped end first, into the bearing recess until it is about 010″ (0.25 mm) below flush.

c. Inject a little grease in the Bearing.

2. Slide the Front End Plate (21), flat side first, over the splined end of the Rotor (18).

3. Using a sleeve that contacts only the inner ring of the Front Rotor Bearing (23), press the Front Rotor Bearing onto the splined hub of the Rotor until it seats against the Front End plate.

NOTICE: The clearance between the Front End Plate and the Rotor is critical.

4. While holding the Front End Plate, gently tap the splined end of the Rotor until you can insert a 0.001″ feeler gauge or shim between the face of the Rotor and End Plate.

5. Grasp the splined end of the Rotor in copper covered vise jaws so that the short hub of the Rotor is upward.

6. Wipe each Vane (19) with a film of light oil and place a Vane in each slot in the Rotor.

7. Place the Cylinder (20), air port end trailing, down over the Rotor and against the Front End Plate.

8. Place the Rear End Plate (16), flat side first, over the short hub of the Rotor.

9. Install the Rear End Plate Retainer (17) in the groove on the rotor hub.

CAUTION: When installing the Rear End Plate Retainer (17), make certain it does not fly as you slip it on the hub of the Rotor.

10. Smear a film of light grease on the Rear End Plate Gasket (15) and place the Gasket on the End Plate so that the port in the Gasket is aligned with the port in the End Plate.

11. Using an assembly dowel 3/32″ in diameter x 10″ long (2.3 mm x 254 mm), align the dowel groove in the Front End Plate, Cylinder, Rear End Plate and Gasket. Place the assembly rod in the aligned grooves so that about 3″ of the rod extends beyond the Rear End Plate. Insert the extension in the dowel hole at the bottom of the housing bore, and slide the motor into the Motor Housing until it seats.

12. Withdraw the assembly dowel and insert the Cylinder Dowel (22).

13. Place the two Bearing Spring Washers (26) inside the Front Rotor Bearing Housing (24) and against the Front Rotor Bearing Retainer (25).

14. Slide the Front Rotor Bearing Housing over the Front Rotor Bearing.

15. Install the Exhaust Deflector Rear Seal (30) on the Motor Housing.

16. Install the Exhaust Diffuser (29A) on the hub of the Motor Housing.

1. If the Planet Gear Bearings (34) were removed, press the new Bearings into the Arbor Planet Gears (33) using a bearing inserting tool (see drawing TPD786) that has a pilot and that contacts the outer radius of the Bearings. Press against the stamped end of the Bearing.

2. Smear Ingersoll Rand No. 28 grease on the Bearings and teeth of the Planet Gears.

3. Using blocks or a ring on the table of an arbor press, place the large shoulder of the Arbor (32), threaded end down, on the blocks or the ring.

4. Position one of the assembled Arbor Planet Gears in one of the machined Arbor openings, carefully aligning the center of the Gear with the hole in the shoulder of the Arbor, and press one of the Arbor Planet Gear Shafts (35) into the Arbor and through the Gear. Make certain both ends of the Shaft are below the faces of the Arbor.

5. Repeat the previous step with the second Planet Gear.

6. For Models 7S48L, and 7S60L, grease the teeth of the Rotor Pinion (36) and insert it into the center of the Arbor through the remaining machined opening. Make certain the teeth of the Rotor Pinion mesh with the teeth of the Planet Gears.

7. Install the remaining Arbor Planet Gear making certain all gearing meshes and moves freely.

CAUTION: Do not press against the Rear Arbor Bearing.

8. Press the Rear Arbor Bearing (37) onto the shaft at the unthreaded end of the Arbor.

9. Reposition the Arbor on the pressing table with the threaded end up.

10. Position the Arbor Bearing Spacer (38) on the Arbor and press the Front Arbor Bearing (39), shielded side up, onto the Arbor.

11. Smear some grease on the internal spline of the Gear Case (40) and insert the assembled Arbor, gearing end fast, into the unsplined end of the Gear Case. Make certain the teeth of the Planet Gears mesh with the teeth in the Gear Case.

12. Using snap ring pliers, install the Arbor Bearing Retainer (42) in the front end of the Gear Case.

13. Thread the Inner Wheel Flange (43) onto the Arbor. Using two 5/8-11 jam nuts on the end of the Arbor, tighten the Inner Wheel Flange.

14. Lubricate and install the Exhaust Deflector Front Seal (31) in the annular groove of the Gear Case.

15. Being careful not to cut the Seal, slide the smaller end of the Exhaust Deflector (28) onto the Gear Case until it butts against the shoulder of the Gear Case.

16. If the Exhaust Silencer (29) was removed, fold the Silencer in half lengthwise and work it into the open area between the Exhaust Deflector and the Gear Case.

1. Grasping the handle of the Motor Housing in a vise with the spline of the Rotor upward, place the Bearing Housing Spacer (27) on the face of the Front Rotor Bearing Housing.

2. Position the Gear Case and Exhaust Deflector over the Motor Housing and while slowly rotating the Arbor to align the Planet Gears with the spline of the Rotor, screw the Gear Case onto the Motor Housing. Make certain the Exhaust Deflector Rear Seal is not cut while threading the Gear Case onto the Motor Housing.

3. With a torque wrench on the flats on the Gear Case, tighten the Gear Case to between 50 to 60 ft-lb (67.8 to 81.4 Nm) torque.

4. Install the Pad Mounting Spacers (44) on the Arbor.

5. Thread the Sanding Pad (46) and the Pad Mounting nut onto the Arbor.

6. Spin the Sanding Pad by hand to make certain nothing is binding and remove the tool from the vise.

The troubleshooting table for “Low power or low free speed” on the INGERSOLL RAND 7P24L Air Sander is as follows:

The troubleshooting table for “Rough operation” on the INGERSOLL RAND 7P24L Air Sander is as follows:

The troubleshooting table for “Scoring” on the INGERSOLL RAND 7P24L Air Sander is as follows:

The troubleshooting table for “Air leaks” on the INGERSOLL RAND 7P24L Air Sander is as follows: