3 Inch - AirVANTAGE TOOLS
Contents
1. Lightly grease the O Ring and place it on the Speed Con trol Install the Valve Stem and O ring cleaned and lightly greased and insert the Speed Control into Housing in the midway position Install Retaining Ring CAUTION Make sure the Retaining Ring is completely snapped into groove in the Housing 3 Install the Valve Seat Valve and the Spring Coat the threads of the Inlet Bushing Assembly with 1 or 2 drops of Loctite 222 or equivalent non permanent pipe thread sealant Screw the Inlet Bushing Assembly into the inlet port on the Housing Torque to 60 in Ibs 6 77 Nm 4 For NV and CV machines follow the steps A C For SGV machines follow the steps G J This section is for Central Vacuum CV and Non Vacu um NV machines A Place a clean Muffler all the way into the chamber of the Muffler Housing Press the Bronze Muffler into the bore of the Muffler Housing if applicable B Screw the Muffler Housing assembly into the Housing until hand tight Use a 21 mm socket torque wrench combination to torque the Muffler Housing Torque to 20 in lbs 2 25 Nm For NV machines move onto For CV machines move onto step D C Install the 3 in 77 mm Non Vacuum Shroud onto the Housing by working the Shroud over and around the bot tom of the Housing flanges Make sure the line up slots on the Housing and tabs on the Shroud are engaged Move onto the Spindle Bearings AirSHIELD and Shaft Balancer Assembly Section This2. Lock Ring Secure the motor assembly by clamping the Shaft Balancer in a padded jaw vise and remove the Retaining Ring from the end of the Shaft Balancer and the O ring from the Cylinder Remove the Rear Endplate This may require support ing the Rear Endplate with a bearing separator Use a light press force to push the Shaft Balancer through the Bearing Then remove the Cylinder Vanes and the Rotor Remove the Key from the Shaft Balancer Support the Front Endplate with a bearing separator and use a light press force to push the Shaft Balancer through the bear ing It may be necessary to remove the Bearing with a bearing separator if it came out of the Front Endplate and stuck to the shaft of the Shaft Balancer Remove the Bearing s from the Endplates by using the T 8 Endplate Bearing Removal Tool to press out the Bearings Shaft Balancer and Spindle Disassembly 1 Grip the shaft end of the Shaft Balancer in a padded vise With a thin screwdriver pick out the slotted end of the Retaining Ring and peel out Screw the female end of the T 11 5 16 24 to 1 4 20 Adapter into the male end of the Service Wrench Screw the Service Wrench assembly into the Spindle Assembly until hand tight Apply a gentle heat from a propane torch or hot air gun to the large end of the Shaft Balancer until it is about 212 F 100 C to soften the adhesive Do not over heat Remove the Spindle Assembly by using the Slider to give sha
3. be highly combustible Vacuum dust collection bag should be cleaned or replaced daily Cleaning or replacing of bag also assures optimum performance 11 Do not exceed maximum recommended air pressure Use safety equipment as recommended 12 The tool is not electrically insulated Do not use where there is a possibility of coming into contact with live electricity gas pipes water pipes etc Check the area of operation before operation 13 Take care to avoid entanglement with the moving parts of the tool with clothing ties hair cleaning rags etc If entangled it will cause the body to be pulled towards the work and moving parts of the machine and can be very dangerous 14 Keep hands clear of the spinning pad during use 15 If the tool appears to malfunction remove from use im mediately and arrange for service and repair 15 Do not allow the tool to free speed without taking precau tions to protect any persons or objects from the loss of the abrasive or pad Closed Loop Pipe System Sloped in the direction of air flow To Tool Station Filter Regulator Lubricator Ball Valve Air Flow Air Dryer Air Hose Air Compressor and Tank Figure 1 AirVANTAGE Back Up Pads AirVANTAGE back up pads are perfectly mated for use on the AirVANTAGE LP Constructed from premium indus trial quality materials and featuring a riveted fiberglass and steel hub with molded urethane their durabili
4. click when the lead thread of the lock ring drops into the lead thread of the housing then turn clockwise to tighten 8 Spin on a new Pad and hand tighten it using a 17 mm Pad Wrench Testing Place 3 drops of quality pneumatic air tool oil directly into the motor inlet and connect to a 90 psig 6 2 bar air sup ply The tool should run between 9 500 RPM and 10 500 for 10 000 RPM machines or 11 500 and 12 500 RPM for 12 000 RPM machines when the air pressure is 90 psig 6 2 bar at the inlet of the tool while the tool is running at free speed This free speed will be about 500 RPM to 1 000 RPM less when a Vacuum or Hook Face Pad is used because of wind resistance This will not affect performance when sanding Loctite is a registered trademark of the Loctite Corp Revision 05 06 10 Troubleshooting Guide Symptom Possible Cause Solution Low Power and or Low Free Speed Insufficient Air Pressure Check air line pressure at the Inlet of the Sander while the tool is running at free speed It must be 90 psig 6 2 Bar Clogged Muffler s See the Housing Disassembly section for Muffler removal The Muffler can be back flushed with a clean suitable cleaning solution until all contaminates and obstructions have been removed If the Muffler can not be properly cleaned then replace it Replace Muffler Insert See the Housing Assembly Section Plugged Inlet Screen Clean the Inlet Screen
5. engaged Slide the SuperVAC SGV Exhaust Adapter Fitting into the exhaust of the 3 in 77 mm SuperVAC CV Shroud DOC 0254 H Lightly grease two O Rings and place them into the two grooves in the SGV Retainer Put the SGV Retainer into the mounting hole of the 1 28 mm Hose SGV Swivel Exhaust Assembly Standard or the in 19 mm Hose SGV Swivel Exhaust As sembly Optional Slide the Swivel Exhaust Assembly into the SuperVAC SGV Exhaust Adapter Fitting while at the same time inserting the SGV Retainer into the sander Housing exhaust port Screw the SGV Retainer into the threaded exhaust port on the Housing with an 8 mm hex key Torque to 45 5 08 Nm Spindle Bearings AirSHIELD and Shaft Balancer Assembly 1 Place the T 5A Spindle Bearing Pressing Tool Base onto a flat clean surface of a small hand press or equivalent with the spindle pocket facing upward Place the Spindle into the spindle pocket with the shaft facing upwards See Figures 1 and 2 2 Place theWasher on the Spindle shaft with the curve of the Washer facing out so that the outside diameter of the Washer will contact the outer diameter of the Bearing one seal Lay the Shim on the shoulder of the Spindle Place the Bearing one seal on the Spindle with the seal side toward the Washer NOTE Make sure that both the inner and outer races of the Bearings are supported by the Bearing Press Tool when pressing them
6. into place Press the Bearing onto the shoulder of Spindle using the T 5B Spindle Bearing Pressing Tool Top as shown in Figure 2 3 Place the Shim over the Spindle shaft and onto the face of the Bearing making sure it is on center Press the no seals shields Bearing down using the T 5A Spindle Bearing Pressing Tool Top being careful to make sure the Shim is still centered on the vertical axis of the Spindle shaft and Bearing See Figure 3 NOTE When the Spindle Assembly is done correctly the Bearings will rotate freely but not loosely and the Shim can be moved but will not slide or move by gravity 4 Secure the Retaining Ring onto the Spindle Assembly making sure it is completely snapped into the groove Set the Spindle Assembly aside 5 Take the Filter and center it on the small bore that the original filter was in before removal With a small diameter screwdriver or flat end rod press the Filter into the bore until it is flat in the bottom of the bore Place the Valve into the bore so it is oriented correctly then press the Retainer into the bore until it is flush with the bottom of the bearing bore 6 Apply a pin head size drop of 271 Loctite or equivalent to the outside diameter of each of the bearings on the Spindle Assembly Spread the drop of bearing locker around both bearings until distributed evenly CAUTION Only a very small amount of bearing locker is needed to prevent rotation of the bearing OD Any excess will mak
7. sander can develop a torque reaction See the section Operating Instructions Putting the Tool into Service Use a clean lubricated air supply that will give a measured air pressure at the tool of 90 psig 6 2 bar when the tool is running with the lever fully depressed It is recommended to use an approved 3 8 in 10 mm x 25 ft 8 m maximum length airline It is recommended that the tool be connected to the air supply as shown in Figure 1 Do not connect the tool to the airline system without incorpo rating an easy to reach and operate air shut off valve The air supply should be lubricated It is strongly recommended that an air filter regulator and lubricator FRL be used as shown in Figure 1 as this will supply clean lubricated air at the correct pressure to the tool Details of such equipment can be obtained from your supplier If such equipment is not used then the tool should be manually lubricated To manually lubricate the tool disconnect the airline and put 2 to 3 drops of suitable pneumatic motor lubricating oil such as Fuji Kosan FK 20 Mobil ALMO 525 or Shell TORCULA 32 into the hose end inlet of the machine Reconnect tool to the air supply and run tool slowly for a few seconds to allow air to circulate the oil If the tool is used frequently lubricate it on a daily basis or lubricate it if the tool starts to slow or lose power It is recommended that the air pressure at the tool be 90 PSI 6 2 Bar while th
8. section continued from Section for Central Vacuum CV Exhaust machines D Install the 3 in 77 mm SuperVAC CV Shroud on to the Housing by working the shroud over and around the bottom of the Housing flanges Make sure the line up slots on the Housing and tabs on the Shroud are engaged Slide the inlet end of the 19 mm SuperVAC CV Swivel Exhaust Assembly Standard or the 1 in 28 mm SuperVAC CV Swivel Exhaust Assembly Optional into the exhaust port of the 3 in 77 mm Su perVAC CV Shroud until it hits the stop on the Super VAC CV Swivel Exhaust Assembly Make sure the key on the SuperVAC CV Swivel Exhaust Assembly bracket is aligned and engaged with the keyway on the Housing F Place the Washer over the Screw Thread the screw into the mounting hole of the 34 in 19 mm Super VAC CV Swivel Exhaust Assembly or 0 1 in 28 mm SuperVAC CV Swivel Exhaust Assembly Optional and Housing until the end of the screw is flush with the inside surface of the Housing Place the Nut into the cavity of the Housing and thread the screw into the nut until tight Move onto the Spindle AirSHIELD and Shaft Balancer Assembly Section For Self Generated Vacuum SGV Exhaust machines G Install the 3 in 77 mm SuperVAC Shroud onto the Housing by working the shroud over and around the bot tom of the housing flanges Make sure the line up slots on the Housing and tabs on the Shroud are
9. 0309 3 x 3 16 in 5 0 mm ORBIT SHAFT BALANCER 1 AVB0349 3 x 5 16 8 0 mm ORBIT SHAFT BALANCER 1 14 0122 FILTER 1 15 0121 DUCKBILL CHECK VALVE 1 16 0120 VALVE RETAINER 1 17 0107 RETAINING RING 1 18 0162 BEARING NO SEAL SHIELDS 1 19 0196 SPACER 1 20 0161 BEARING 1 SEAL 1 21 AVA0108 SHIM 1 22 AVA0126 BELLEVILLE WASHER 1 23 0177 RETAINING RING 1 24 0083 SPINDLE 1 25 AVA0090 RETAINING RING 1 26 0938 DOUBLE ROW ANGULAR CONTACT BEARING 1 SEAL 1 27 0016 SPACER 1 28 0017 BELLEVILLE WASHER 1 29 AVA0018 RETAINING RING 1 30 0312 SPINDLE 1 AVA0332 THROTTLE LEVER 3 32 2 5 mm ORBIT 12 000 RPM ROS 1 31 AVA0070 THROTTLE LEVER 3 16 in 5 mm ORBIT 12 000 RPM ROS 1 AVA1712 THROTTLE LEVER 5 16 in 8 mm ORBIT 12 000 RPM ROS 1 32 0031 LEVER SPRING PIN 1 0007 2 1 2 in 65 mm GRIP Optional 33 0008 2 3 4 in 69 mm GRIP 1 0009 3 75 mm GRIP Optional 34 AVA0230 HOUSING 1 35 0008 VALVE STEM ASSEMBLY 1 36 0043 O RING 1 27 0014 SPEED CONTROL 1 38 0039 INTERNAL RETAINING RING 1 39 0046 NON VAC SHROUD 1 40 0047 SuperVAC SKIRT 3 32 2 5 mm ORBIT 1 AVC0243 SuperVAC SKIRT 3 16 5 mm amp 5 16 in 8 mm ORBIT 1 41 0146 17 mm WRENCH 1 42 N A 1 Back up Pad supplied with each tool type determined by model 1 43 0
10. 062 INTERNAL MUFFLER 1 44 0068 MUFFLER INSERT 1 45 0166 MUFFLER HOUSING 1 46 0009 VALVE SEAT 1 47 0007 VALVE 1 48 0014 VALVE SPRING 1 49 0013 INLET BUSHING ASSEMBLY 1 50 0006 SGV RETAINER 1 51 0044 O RING 2 52 0857 _ 3 4 19 mm HOSE SEAL W INSTRUCTION Optional 0933 1 28 mm HOSE SEAL TAG W INSTRUCTION 1 53 0778 1 28 mm HOSE SEAL 1 54 0854 3 4 19 mm HOSE SEAL Optional 55 0410 ASSEMBLY FOR 1 28 mm HOSE SuperVAC SGV SWIVEL EXHAUST FITTING 1 56 AVA0409 ASSEMBLY FOR 3 4 in 19 mm HOSE SuperVAC SWIVEL EXHAUST FITTING Optional 57 AVA0300 0 3 4 VAC HOSE 3 4 in x 1 28 mm ADAPTER COUPLING AND AIRLINE ASSM 1 58 0411 0 3 4 VAC HOSE TO DOUBLE BAG FITTING AND AIRLINE ASSY Optional AVA0412 1 in VAC HOSE TO DOUBLE BAG FITTING AND AIRLINE ASSY 1 59 0108 SuperVAC SGV SKIRT SHROUD ADAPTER 1 60 0099 ROS SuperVAC 1 28 mm SWIVEL EXHAUST ASSEMBLY Optional 61 0048 FLANGED NUT 1 62 0205 ROS SuperVAC CV 3 4 in SWIVEL EXHAUST ASSEMBLY 1 63 0047 WASHER 1 64 0769 HEX SOCKET BUTTON HEAD MACHINE SCREW 1 65 0468 VACUUM BAG 1 66 0470 VACUUM BAG INSERT 1 DOC 0254 Revision 05 06 10 Product Configuration Specifications 12 000 RPM 3 in Light Weight Random Orbital Sander Note All Self Generated Va
11. Airline Recommended Maximum Air Pressure Size Minimum Hose Length Maximum Working Pressure 6 2 bar 90 psig 10 mm 3 8 in 8 meters 25 feet Recommended Minimum NA NA Please Read and Comply with 1 General Industry Safety amp Health Regulations Part 1910 OSHA 2206 available from Superintendent of Docu ments Government Printing Office Washington DC 20402 2 Safety Code for Portable Air Tools ANSI B186 1 available from American National Standards Institute Inc 1430 Broadway New York New York 10018 3 State and Local Regulations Proper Use of Tool This sander is designed for sanding all types of materials i e metals wood stone plastics etc using abrasive designed for this purpose Do not use this sander for any other purpose than that specified without consulting the manufacturer or the manufacturer s authorized supplier Do not use back up pads that have a working speed less than 12 000 RPM free speed Never use back up pads that have a weight and or size different than the machine was specifically designed for AirVANTAGE Warranty All AirVANTAGE Random Orbital Sanders are warranted for defects in materials or workmanship for one year from the date of delivery to the user Combined with the AirVANTAGE name this Warranty expresses our total confidence in the superior quality durability and performance of the AirVANTAGE LP To receive any expressed or implied warranty tool must be repaired by an author
12. OL KIT T 1 ROS SPINDLE 1 T 5 LW ROS SPINDLE BEARING PRESS TOOL T 11 5 16 24 to 4x20 SPINDLE 5 PULLER ASSEMBLY AVA0490 3 in LW ROS SERVICE TOOL KIT Service Kit 0746 AirVANTAGE Overhaul Service Kit contains all the replacement parts that naturally wear over time straightforward manual to make servicing an AirVANTAGE sander simple Overhauling the Random Orbital Sander be made even easier with the use of the above Service Tools The Service Tools also reduce the chance of improper assembly DOC 0254 0746 Overhaul Service Kit Contents Part No Description Qty 0040 External Retaining Ring 1 0021 Bearing 2 Shields 1 AVA0042 O Ring 1 0010 Vanes 5 AVB0005 Rotor 1 AVA0041 Key 1 AVA0019 Bearing 2 Shields 1 AVA0162 Bearing No Seals Shields 1 AVA0196 Shim 1 AVA0161 Bearing 1 Seal 1 0008 Valve Stem Assembly 1 AVA0043 O Ring 1 0039 Internal Retaining Ring 1 0062 Bronze Muffler 1 0068 Muffler 12 000 1 0166 Muffle Housing 1 0009 Valve Seat 1 0007 Valve 1 0014 Valve Spring 1 AVA0254 3 in 77mm LW 12 000 RPM ROS Manual 1 Revision 05 06 10 12 000 RPM Muffler Kit Reorder P N AVA0292 gt Endplate Bearing Kit Reorder P N AVA0614 DOC 0254 Sander Spare Parts Ki
13. OPERATOR S MANUAL FOR AirVANTAGE 12 000 RPM 3 in 77 mm Light Weight RANDOM ORBITAL SANDERS AirVANTAGE TOOLS Declaration of conformity AirVANTAGE Tools 10018 Lower Azusa Road Unit C El Monte California 91731 USA declare on our sole responsibility that the products 3 in LW Random Orbital Sanders See Product Configuration Specifications Table for particular Model to which this declaration relates is in conformity with the following standard s or other normative document s EN ISO 15744 2008 Following the provisions of 89 392 EEC as amended by 91 368 EEC amp 93 44 EEC 93 68 EEC Directives and consolidating Directive 2006 42 EC Place and date of issue Name Signature or equivalent marking of authorized person Operator Instructions Important Includes Please Read and Comply Proper Use of Tool Warranty Product Configuration and Specifications Table Parts Page Parts List Back Up Pads Work Stations Putting the Tool Into Service Operating Instructions and Compressor Layout Read these instructions care fully before installing operating servicing or repairing this tool Keep these instructions in a safe accessible location Manufacturer Supplier i Required Personal Safety Equipment 10018 Lower Azusa Road Unit Safety Glasses Breathing Masks Monte California 91731 USA Tel 626 575 4568 Fax 626 575 4968 Safety Gloves Ear Protection Recommended
14. VAC CV Swivel Exhaust Assembly Optional from the 3 in 77 mm SuperVAC Shroud E Remove the 3 in 77 mm SuperVAC Shroud from the Housing Move onto step 2 For Self Generated Vacuum SGV Exhaust machines F Unscrew the SGV Retainer with an 8 mm hex key Remove the 1 in 28 mm Hose SGV Swivel Ex haust Assembly Standard or 34 in 19 mm Hose SGV Swivel Exhaust Assembly Optional from the SuperVAC Adapter H Pull the SGV Retainer out of the bore of the Swivel Exhaust Assembly and remove the two O Rings Remove the 3 in 77 SuperVAC Shroud from the Housing 2 Place the Speed Control to the midway position and remove the Retaining Ring NOTE If the machine is one of the vacuum models the vacuum exhaust assembly must be removed See section 1 above for removal before the Retaining Ring can be removed with lock ring pliers The Speed Control will now pull straight out Remove the O ring 3 Unscrew the Inlet Bushing Assembly from the Housing Remove the Spring Valve Valve Seat Valve Stem and the O ring from the Valve Stem 4 Press out the Spring Pin from the Housing and remove the Lever ASSEMBLY INSTRUCTIONS NOTE All assembly must be done with clean dry parts and all bearings are to be pressed in place by the correct tools and procedures as outlined by the bearing manufacturers Revision 05 06 10 Housing Assembly 1 Install Throttle Lever into Housing with Spring Pin 2
15. at the handle Part 1 General and EN 8662 8 1997 Hand held portable power tools Measurement of vibration at the handle Part 8 Polishers and rotary orbital and random orbital sanders Specifications subject to change without prior notice values stated in the table are from laboratory testing in conformity with stated codes and standards and are not sufficient for risk evalua tion Values measured in a particular work place may be higher than the declared values The actual exposure values and amount of risk or harm experienced to an individual is unique to each situation and depends upon the surrounding environment the way in which the individual works the particular material being worked work station design as well as upon the exposure time and the physical condition of the user AirVANTAGE can not be held responsible for the consequences of using declared values instead of actual exposure values for any individual risk assessment Further occupational health and safety information can be obtained from the following websites http europe osha eu int Europe http www osha gov USA DOC 0254 Revision 05 06 10 Work Stations The tool is intended to be operated as a hand held tool It is always recommended that the tool be used when standing on a solid floor It can be in any position but before any such use the operator must be in a secure position having a firm grip and footing and be aware that the
16. cuum machines use 1 2 28 mm Vacuum Hose Fittings Standard 34 in 2 19 is available All Central Vacuum machines use in 2 19 mm Vacuum Hose Fittings Standard 1 in 2 28 mm is available All 3 machines are shrouded with 1 4 20 male pad attachment Product Net Height ee Pad Pad Part Length Power HP Air Consumption Noise Level Vibration Uncertainty ret Face vac Type Modal Number 0 aah inch mm watts scfm LPM dBA Level m s Factor 4 030200 1232100 1 3 0 6 3 1 78 7 4 9 124 3 28 209 17 481 80 2 0 1 0 acuum Central Vinyl 030234 1232110 1 4 0 65 3 1 78 7 7 3 186 2 28 209 17 481 80 2 0 1 0 Sc Gen 030267 1232110 1 5 0 67 3 1 78 7 7 5 190 1 28 209 17 481 84 2 6 1 3 3 32 in Vacuum 5 0 i 2 5 mm Non 030201 1232102 1 3 0 6 3 1 78 7 4 9 124 3 28 209 17 481 80 2 0 1 0 Central Hook Vacu m 030235 1232112 1 4 0 65 3 1 78 7 7 3 186 2 28 209 17 481 80 2 0 1 0 Self Gen 030268 1232112 1 5 0 67 3 1 78 7 7 5 190 1 28 209 17 481 84 2 6 1 3 The noise test is carried out accordance with EN ISO 15744 2008 Measurement of noise emission from hand held non electric power tools The vibration test is carried out in accordance with EN 28662 1 Hand held portable power tools Measurement of vibration
17. ders Pad face that was not specifically designed to be used with the Pad and Sander Improper lubrication or buildup of foreign debris Disassemble the Sander and clean ina suitable cleaning solution Assemble the Sander See Service Manual Worn or broken Rear or Front Motor Bearing s Replace the worn or broken Bearings See Motor Disassembly and Motor Assembly For vacuum machines it is possible to have too much vacuum while sanding on a flat surface causing the pad to stick to the sanding surface For SGV machines add extra washer s to the pad spindle to increase the gap between the pad and shroud For CV machines reduce vacuum through the vacuum system and or add extra washer s to the pad DOC 0254 11 Revision 05 06 10
18. e future removal difficult Place the Spindle Assembly into the bore of the Shaft Balancer and secure with the Retaining Ring CAUTION Make sure that the Retaining Ring is completely snapped into the groove in the Shaft Balancer Allow the adhesive to cure Revision 05 06 10 Press Tool Top Bearing Washer Shin Press Tool Base Spindle eee T 5A Figure 1 Figure 2 Figure 3 Motor Assembly 1 Use the larger end of the T 13 Bearing Press Sleeve to Press the front Bearing with 2 Shields onto the shaft of the Shaft Balancer 2 Slide the Front Endplate with the bearing pocket fac ing down onto the Motor Shaft Gently press the Front Endplate onto the front Bearing using the larger end of the T 13 Bearing Press Sleeve until the front Bearing is seated in the bearing pocket of the Front Endplate CAU TION Only press just enough to seat the bearing into the pocket Over pressing can damage the bearing 3 Place the Key into the groove on the Shaft Balancer Place the Rotor onto the shaft of the Shaft Balancer mak ing sure that it is a tight slip fit 4 Oil the five Vanes with a quality pneumatic tool oil and place in the slots in the Rotor Place the Cylinder As sembly over the Rotor with the shorter end of the Spring Pin engaging the blind hole in the Front Endplate NOTE The Spring Pin must project 060 in 1 5 mm above the flanged side of the Cylinder 5 Press fit the r
19. e tool is running so the maximum RPM is not exceeded The tool can be run at lower pressures but should never be run higher than 90 PSI 6 2 Bar If run at lower pres sure the performance of the tool is reduced Operating Instructions 1 Read all instructions before using this tool All operators must be fully trained in its use and aware of these safety rules All service and repair must be carried out by trained personnel 2 Make sure the tool is disconnected from the air supply Select a suitable abrasive and secure it to the back up pad Be careful and center the abrasive on the back up pad 3 Always wear required safety equipment when using this tool 4 When sanding always place the tool on the work then start the tool Always remove the tool from the work before stopping This will prevent gouging of the work due to excess speed of the abrasive 5 Always remove the air supply to the sander before fitting adjusting or removing the abrasive or back up pad 6 Always adopt a firm footing and or position and be aware of torque reaction developed by the sander 7 Use only correct spare parts 8 Always ensure that the material to be sanded is firmly fixed to prevent its movement 9 Check hose and fittings regularly for wear Do not carry the tool by its hose always be careful to prevent the tool from being started when carrying the tool with the air supply connected DOC 0254 To Coupler at or near Tool 10 Dust can
20. ear 2 Bearing 2 shields into the Rear Endplate with the T 1B Bearing Press Tool Make sure the T 1B Press Tool is centered on the O D of the outer race Lightly press fit the Rear Endplate and Bearing Assembly over the Shaft Balancer using the small end of the T 13 Bearing Press Sleeve The sleeve should press only the inner race of the bearing IMPORTANT The Rear End plate and Bearing Assembly is pressed correctly when the Cylinder is squeezed just enough between the Endplates to stop it from moving freely under its own weight when the shaft is held horizontal but be able to slide between the Endplates with a very light force If pressed to tightly the motor will not run freely If the pressed assembly is to loose the motor will not turn freely after assembly in the Housing DOC 0254 10 6 Secure the assembly by placing the Retaining Ring in the groove of the Shaft Balancer CAUTION The Retaining Ring must be placed so that the middle and two ends of the hoop touch the Bearing first Both raised center por tions must be securely snapped into the groove in the Shaft Balancer by pushing on the curved portions with a small screwdriver 7 Carefully screw the Lock Ring into the Housing using the T 6 Motor Lock Ring Wrench Torque to 60 in Ibs 6 77 Nm NOTE A simple technique to assure first thread engagement is to turn the lock ring counter clockwise with the service tool while applying light pressure You will hear and feel a
21. ized AirVANTAGE Service Center The Service Instructions section in this document is provided for use after completion of the warranty period To receive warranty tools must be operated under the conditions as described in the Putting the Tools into Service section of this document and be connected to an air supply system as shown in Figure 1 Tools that have been exposed to extreme conditions will be covered under warranty at the sole discretion of AirVANTAGE o Original Instructions DOC 0254 1 Revision 05 06 10 Parts Page Bee TO VACUUM SYSTEM FOR ce VACUUM Gin n 5 mm ORBIT 8 mm ORBIT DOC 0254 2 Revision 05 06 10 Parts List Item Part No Description Qty 1 0040 EXTERNAL RETAINING RING 1 2 0021 BEARING 2 SHIELDS 1 3 AVA0065 REAR ENDPLATE 1 4 0067 CYLINDER ASSEMBLY 1 5 0042 O RING 1 6 0005 1 7 0010 VANE 5 8 0041 WOODRUFF KEY 1 9 0064 FRONT ENDPLATE 1 10 0019 BEARING 2 SHIELDS 1 11 0045 O RING 1 12 0001 LOCK RING 1 AVB0084 3 x 3 32 2 5 ORBIT SHAFT BALANCER 1 13 AVB
22. rp outward blows to the Spindle Allow the parts to cool so they are safe to handle Remove the Retaining Ring from the Spindle Assembly Use a small Bearing Separator to remove the Bearing Shim Bearing Shim and the Washer from the Spindle Assembly The AirSHIELD components are held in place by the DOC 0254 light press fit of the Retainer These components can be damaged during removal and may need to be replaced if removed To remove the Retainer use an O ring pick or a 8 sheet metal screw to grip and pull out the Retainer Remove the Valve and Filter from the bore in the Shaft Balancer If the Retainer and Valve were not damaged they can be reused However the Filter should be re placed on re assembly Housing Disassembly 1 For Non Vacuum NV and Central Vacuum CV ma chines follow steps below unless otherwise noted For Self Generated Vacuum SGV machines disregard steps and move onto Step below A Unscrew the Muffler Housing from the Housing Remove the Bronze Muffler from the Muffler Housing if applicable Remove the Muffler from the Muffler Housing For NV machines move onto B For CV machines move onto C B Remove the 3 in 77 mm Non Vacuum Shroud For NV machines move onto step 2 For Central Vacuum CV Exhaust machines C Remove the Screw Washer and Nut D Remove the 19 mm SuperVAC CV Swivel Exhaust Assembly Standard or the 1 28 Super
23. ts 1 4 18 NPT Air Inlet Kit Spindle Bearing Kit Reorder P N AVA0610 Reorder P N AVA0618 E O o Speed Valve Kit Rotor Vanes and Key Kit Reorder P N AVA0711 Reorder P N AVA0709 7 Revision 05 06 10 12 000 RPM 3 in 77 mm LW ROS Service Instructions NOTICE To receive any expressed or implied warranty the tool must be repaired by an authorized Service Center The 3 in 77 mm Light Weight Random Orbital Sander Service Instructions section provided is for use after completion of the warranty period DISASSEMBLY INSTRUCTIONS Changing Grips 1 The Grip has two tabs that wrap around the body of the sander under the inlet and exhaust Use a small screwdriver to pick out one of the tabs of the Grip then continue to go underneath the Grip with the screwdriver and pry the Grip off the sander To install a new Grip hold the Grip by the tabs making them face outward align the Grip and slide it under the Throttle Lever then press the Grip down until it seats onto the top of the sander Make sure the two tabs seat under the inlet and exhaust Motor Disassembly 1 Lightly secure the tool in a vise using the T 7 Service Col lar or padded jaws Use a 17 mm Pad Wrench to secure the Spindle and spin the Pad counter clock wise off the spindle Remove the Lock Ring with the T 6 Motor Lock Ring Wrench Spindle Puller Tool The motor assembly can now be lifted out of the Housing Remove the O Ring from the
24. ty and precise construction are the ideal complement to the performance of the AirVANTAGE LP See Product Configuration Specifi cations Table for the correct replacement pad for a particular model Description Part 3 low profile 1 4 20 non vacuum vinyl face 1232100 3 low profile 1 4 20 non vacuum hook face 1232101 3 low profile 1 4 20 non vacuum j hook face 1232102 3 low profile 1 4 20 vacuum vinyl face 1232110 3 low profile 1 4 20 vacuum hook face 1232111 3 low profile 1 4 20 vacuum j hook face 1232112 Revision 05 06 10 SERVICE INSTRUCTIONS FOR AirVANTAGE 12 000 RPM in 77 mm Light Weight RANDOM ORBITAL SANDERS Service Tools Accessories AirVANTAGE TOOLS When an AirVANTAGE LP ROS needs to be serviced we offer tool kits or individual tools to make the disassembly assem bly fast and easy The Service Tools are highly recommended for use with the Overhaul Service Kit NOTICE To receive any expressed or implied warranty tool must be repaired by an authorized AirVANTAGE Service Center The following general service instructions provided are for use after completion of the warranty period T 6 MOTOR LOCK RING WRENCH SPINDLE PULLER T 7 SOFT COLLAR Bo 9 12 mm ID BEARING PULLER BEARING PRESS TOOLS T 8 MOTOR FACE PLATE T 13 BEARING BEARING REMOVAL TOOL PRESS TOOL AVA0486 UNIVERSAL SERVICE TO
25. with a clean suit able cleaning solution If Screen does not come clean replace it One or more Worn or Broken Vanes Install a complete set of new Vanes all vanes must be replaced for proper operation Coat all vanes with quality pneumatic tool oil See Motor Disassembly and Motor Assembly Internal air leakage in the Motor Housing indicated by higher than normal air con sumption and lower than normal speed Motor Parts Worn Check for proper Motor alignment and Lock Ring engagement Check for damaged O Ring in Lock Ring groove Remove Motor Assembly and Re Install the Motor Assembly See Motor Disas sembly and Motor Assembly Overhaul Motor Contact authorized Service Center Worn or broken Spindle Bearings Replace the worn or broken Bear ings See Shaft Balancer and Spindle Disassembly and Spindle Bearings AirSHIELD and Shaft Balancer As sembly Air leakage through the Speed Control and or Valve Stem Dirty broken or bent Valve Spring Valve or Valve Seat Disassemble inspect and replace worn or damaged parts See Steps 2 and 3 in Housing Disassembly and Steps 2 and 3 in Housing Assembly Vibration Rough Operation Incorrect Pad Addition of interface pad or other material Only use Pad Sizes and Weights de signed for the machine Only use abrasive and or interface designed for the machine Do not attach anything to the San
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