Dynabrade 10784, Safety, Operation And Maintenance Manual

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Assembly/Disassembly Instructions
Important: The Manufacturing Warranty is void if the tool is disassembled before the warranty expires by anyone other than a Dynabrade ®
Approved Repair Technician. Notice: A 98224 Motor Tune-Up Kit is available. Also, the special repair tooling referred to in these instructions can be ordered
through your Dynabrade ® Distributor. Please refer to this tool manual for correct part number identification.
Important: Always follow these steps before servicing any part of this air tool.
1. Shut off the air supply and then depress throttle lever to dissipate the remaining air.
2. Carefully disconnect the tool from the air supply hose.
Note: Use a wrench to hold the air tool inlet bushing stationary when removing the air supply connection.
Orbital Head Disassembly:
1. Remove the backing pad from the orbital head by using the 50679 26mm wrench. Insert the wrench in between the backing pad and the orbital
head to hold the 57069 Balancer Shaft stationary while removing the 96168 Screw with a 3/16" hex key.
2. Hold the 18552 Housing in a vise with bronze or aluminum jaws so that the orbital head assembly is facing up.
3. Apply localized heat to the three 95235 Screws and use a 9/64" hex key to remove these.
4. Apply localized heat to the 57069 Balancer Shaft and remove the shaft along with the 56052 Bearing.
5. Use the 96346 2" Bearing Separator and the 96232 #2 Arbor Press to remove the 56052 Bearing from the 57069 Balancer Shaft.
6. Use the 95823 21mm Wrench to remove the orbital head from the spindle.
Orbital Head Disassembly Complete.
Motor Disassembly:
1. Hold the 18552 Housing in a vise with bronze or aluminum jaws so that the 18579 Valve Housing is pointing up.
2. Pull the 18061 Grip off the 18579 Valve Housing. Note : A “Hot Air Gun” can be used to warm the 18601 Grip, making it more flexible.
3. Use the 95331 (4mm) Hex Key to remove the 18580 Screws (4), 18559 Washers (4), 18579 Housing, 18578 Gasket, 18577 Spacer, 18574 O-Ring
and 18576 Gasket.
4. Carefully slide the air motor out of the 18552 Housing. Note : A “Hot Air Gun” can be used to warm and expand the 18552 Housing.
5. Use the 96343 Retaining Ring Pliers to remove the 18567 Retaining Ring.
6. Fasten the 96346 , (2") Bearing Separator carefully between the 18573 Rear Bearing Plate and the 18571 Cylinder and place the separator on the table
of the 96232 , (#2) Arbor Press so that the 18594 Pinion Gear is pointing down.
7. Use a 3/16" dia. flat end drive punch as a press tool to push the 18595 Rotor out of the 18555 Bearing.
8. Use the 96213 Bearing Removal Tool and the arbor press to push the 18555 Bearing out of the 18573 Rear Bearing Plate.
9. Fasten the bearing separator around the flange of the 18594 Pinion Gear so that the flat side of the separator is against the 18568 Bearing. With a
downward motion, strike the flat side of the separator against the table of the arbor press several times. The 18568 Bearing will slide out of the 18569
Front Bearing Plate.
10. Use a 3/16" dia. flat end drive punch as a press tool and the arbor press to push the 18594 Pinion Gear out of the 18568 Bearing.
11. Use a 3/16" dia. flat end drive punch as a press tool and the arbor press to push the 18595 Rotor out of the front 18555 Bearing. Use the 96213 Bearing
Removal Tool and the arbor press to push the 18555 Bearing out of the 18569 Front Bearing Plate.
Motor Disassembly Complete.
Right Angle Gear Disassembly:
1. Use the 95331 (4mm) Hex Key to remove the 18560 Screws (4), and 18559 Washers (4).
2. Fasten the 96346 Bearing Separator under the 18555 Bearing and use a 3/16" dia. flat end drive punch and the 96232 , (#2) Arbor Press to push the
bearing from the spindle.
3. Use the 96343 Retaining Ring Pliers to remove the 18556 Retaining Ring, 18557 Wave Washer, 18593 Bevel Gear, and 18563 Key.
4. Use the 96343 Retaining Ring Pliers to remove the 18562 Retaining Ring, and pull the spindle along with the 18561 Bearing out of the
18902 Spindle Cap.
5. Place the 18561 Bearing on the tool plate of the arbor press and push the spindle out of the bearing.
Right-Angle Gear Disassembly Complete.
Motor Assembly:
1. Use the raised outer portion of the 96240 Bearing Press Tool to install the 18555 Bearing into the 18569 Front Bearing Plate.
Note : Use the 96232 (#2) Arbor Press.
2. Position the 18595 Rotor on the 96231 Tool Plate of the 96232 (#2) Arbor Press so that the rear portion of the rotor body is flat on the tool plate and the
spline end is pointing up. Use the 18571 Cylinder as a jig. Place the cylinder over the rotor so that it is also setting on the tool plate. Slip the front
bearing/plate assembly over the spline end of the rotor and use the raised center portion of the 96240 Bearing Press Tool to install the front
bearing/plate assembly onto the 18595 Rotor. Note : Use approximately 3 lbs. (1364g.) of force. Remove the rotor with the bearing/plate assembly from
the arbor press. Use a .001" (.03mm) thick feeler gage to check the fit of the bearing plate to the face of the rotor. The clearance between the bearing
plate and the face of the rotor should be .001" to .0015" (.03 -.04mm).
3. Place the 18568 Bearing flat on the tool plate of the arbor press and install the 18594 Pinion Gear into the inner race of the bearing.
4. Place the 18569 Front Bearing Plate flat on the tool plate of the arbor press so that the rotor is hanging down. Set the 18568 Bearing on the opening of
the 18569 Front Bearing Plate so that the pinion gear is pointing up. Place one end of the 18571 Cylinder against the outer race of the 18568 Bearing
and using the cylinder as a press tool, push the 18568 Bearing into the front bearing plate.
5. Apply a small amount of the 95842 Dynabrade Air Lube (10W/NR or equivalent) to the 18570 Blades (4) and install them into the 18595 Rotor.
6. Place the 18573 Rear Bearing Plate flat on the tool plate of the arbor press and use the raised outer portion of the 96240 Bearing Press Tool to install
the 18555 Bearing into the rear bearing plate.
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