Disassembly/Assembly Instructions - Right Angle Sanders (cont.)
Spindle Lock Assembly:
1.
Install a new
97156
Ring onto the plunger and apply a small amount of the Dynabrade Air Lube 10W/NR (P/N
95842
or equivalent) to the o-ring and plunger.
2.
Install
98285
Spring onto the housing bushing and insert the
25273
Plunger Assembly through the spring.
3.
Install the plunger assembly into the spindle lock bushing.
Note
: Rotating the plunger while inserting prevents damage to the o-ring.
Spindle Lock Assembly Complete.
Motor Assembly:
1.
Install
01010
Spacer onto the rotor front mandrel.
2.
Select .003" (.08mm) thickness shims from the
01121
Shim Pack and install these into the
25236
Front Bearing Plate.
3.
Install
98242
O-Ring into front bearing plate groove and install
01007
Bearing, into the front bearing plate.
4.
Position the rotor in a vise with aluminum or bronze jaws so that the rotor spindle is pointing up. Install the front bearing/plate onto the rotor.
5.
Apply a small amount of the Loctite
®
#243 (or equivalent) to the external threads on the rotor stem and install the pinion gear. (Torque to 17N·m/150 lbs. in.)
Using a hook/pin spanner wrench. Remove the assembly from the vise.
6.
Use a .001" (0.3mm) thick feeler gauge to check the clearance between the front bearing plate and the face of the rotor. The clearance should be .001"-.0015" (0.3-0.4mm).
Note:
If the clearance needs adjustment repeat steps 2-6 adding or removing shims as required.
7.
Lubricate
25234
Vanes (4) with the
95842
Dynabrade Air Lube 10W/NR (or equivalent) and install these into the rotor.
8.
Install
25235
Cylinder over the rotor so that the air inlet opening of the cylinder will line up with the air inlet opening on the
25237
Rear Bearing Plate.
9.
Install
01206
Bearing into
25237
Rear Bearing Plate.
10.
Use the raised inner diameter of
96244
Bearing Press Tool and the arbor press to install the rear bearing plate onto the rotor.
Note:
Carefully press the bearing/plate down until it just touches the cylinder. This will establish a snug fit between the bearing plates and the cylinder.
11.
Fasten the pinion gear in a vise with aluminum or bronze jaws so that the rear bearing/plate pointing up.
12.
Apply a small amount of the Loctite
®
#567 (or equivalent) to the external threads of governor assembly. Install it onto the rotor using an 19 mm crowfoot and
torque wrench.
LEFT HAND THREAD
Turn counterclockwise. (Torque to 9N·m/80 lbs. in.)
13.
Carefully slide the motor assembly into the housing.
14.
Place padding around the housing and carefully hold the housing stationary in a vise. Apply a small amount of the Loctite
®
#567 (or equivalent) to housing external threads.
Use an adjustable wrench tighten
25257
Cup Nut onto housing. Turn clockwise. (Torque to 30N·m/265 lbs. in.)
Important: Allow 30 minutes for the adhesives to cure before operating the tool.
Run the tool to make sure that the air motor is functioning properly before installing the right angle gears. Motor Assembly Complete.
Spindle/Gear Assembly:
1.
Position the spindle in the arbor press so that the threaded end is pointing down.
2.
Use a 19/32" deep well socket as a press tool, install the
01036
Bearing onto the spindle and against the step.
3.
Use a 19/32" deep well socket as a press tool and install the
25241
Bevel Pinion onto the spindle.
4.
Prepare the
25264
Wick by soaking in
95848
Gear Oil and then install the wick onto the spindle.
5.
Press
02057
Bearing using
96243
Press Tool (
sold separately
) onto spindle until the spindle is flush with the bearing top.
6.
Place padding around the housing and carefully hold the housing stationary in a vise with the right angle spindle opening facing up.
Important: Follow these steps to adjust the fit or “backlash” of the spiral bevel gear/pinion gear.
7.
Install the spindle assembly into the housing align wick shape to housing contour. Mesh bevel and pinion gears together.
8.
Apply a small amount of downward force on the spindle and rotate the spindle 360˚. The rotation should be smooth without any tight feel or binding of the gear teeth. Next,
rotate the spindle forward and backward to check the amount of backlash (free movement between the gear teeth). The correct fit should be minimal backlash without any
binding of the gear teeth. Add or remove shims to adjust the gear “backlash”.
9.
Place the
53609
Felt Seal into the
25265
Retainer recess bore.
10.
Apply a small amount of the Loctite
®
#567 (or equivalent) to the threads of the retainer and use the
97782
Pin wrench to install the retainer onto the housing.
LEFT HAND THREAD
Turn counterclockwise. (Torque to 23N·m/203 lbs. in.)
11.
Re-check the fit of the gears by hand before connecting the tool to the air supply. The correct fit should be minimal backlash without any binding of the gear teeth. Add or
remove shims to adjust the gear fit if necessary.
12.
Use the
95541
Lubricant Gun to apply the
95848
Gear Oil Lubricant required for the lubricating wick prime the plunger before adding gear oil to housing. Inject three full
plunges of the gear oil into the
01041
Gear Oil Fitting on the front of housing.
Note:
Inject three full plunges of gear oil into the lubricant fitting after operating the tool every 24-hour interval of use.
Right Angle Assembly Complete:
Muffler Assembly:
1.
Install
25282
Silencer (Cross section size: 7.5 mm) up and inside recess diameter of
25278
Muffler Cover.
2.
Install the
98281
O-Ring (Cross section size: 2.4 mm) into the inside groove of the muffler cover.
3.
Install the
98282
O-Ring (Cross section size: 2.0 mm) into the outside groove of the muffler cover.
4.
Install
25278
Muffler Cover (the side with the smaller hole) onto
25281
Muffler Stem Assembly.
5.
Install
25283
Silencer (Cross section size: 13 mm) into housing cavity.
6.
Apply a small amount of the Loctite
®
#243 (or equivalent) to the external threads of the
25281
Muffler Stem Assembly. Install the
25217
Muffler Assembly
onto the housing. Rotate
25281
Muffler Stem Assembly until slot aligns with housing raised boss. Thread socket head cap screw into housing using a 5/32" hex key
(Torque to 7N·m/60 lbs. in.).
Muffler Assembly Complete.
Final Assembly:
Important: Allow 30 minutes for the adhesives to cure before operating the tool. Install and properly position all guarding and auxiliary side handle. Before installing
mounting flanges or any abrasive product, the air tool must be tested for proper operation. Follow these steps to verify the correct rated operating speed of the tool.
1.
Supply 3 drops of
95482
Dynabrade Air Lube 10W/NR (or equivalent) into the air inlet bushing of the tool while the throttle lever is depressed. Allowing the oil to flow into
the air motor.
2.
Release the throttle lever.
3.
With the air supply valve in the
OFF
position, carefully connect the tool to the air supply hose.
Note:
Use a wrench to hold the air inlet bushing on the tool stationary when
installing the air supply connection.
4.
Once the tool is connected to the air supply, turn the supply valve to the ON position. Run the tool and use a tachometer to verify the rated operating speed (RPM) of the tool.
The tool should operate within 5% of the maximum rated RPM. The tool RPM must never exceed the maximum rated RPM with the operating air supply pressure reading 90
PSIG (6.2 bar g) at the air inlet of the tool. To adjust free speed add or remove shims. Adding shims will increase the speed, removing shims will reduce the tool free speed.
Once the correct rated operating speed for the tool is verified, disconnect the tool from the air supply and install the proper flanging and abrasive product.
Final Assembly Complete. Tool Assembly Complete.
6