Disassembly/Assembly Instructions - Extension Flapper
Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires.
Please refer to parts breakdown for part identification.
Motor Disassembly:
1.
Disconnect tool from power source. Remove collet cap and abrasive.
2.
Using an adjustable wrench, remove
51076
Housing Spindle by turning counter-clockwise.
3.
Remove
53552
Spindle by securing
53551
Coupling Nut in a vise, and loosening
01435
Collet Body.
4.
Secure motor housing using padded vise with motor spindle facing upwards.
5.
Using an adjustable wrench, remove
53550
Adapter, roll back
53175
Collar.
6.
Pull
51072
Coupler from housing. Remove
51066
Rotor Nut with an adjustable wrench, twist rotor nut from shaft.
7.
Grab onto
01148
Rotor and pull motor assembly from motor housing.
8.
Press
01148
Rotor from
01245
Rear Bearing Plate. Press
01015
Rear Bearing from rear bearing plate.
9.
Remove
01013
Cylinder and
01011
Rotor Blades from rotor.
10.
Press rotor through
01007
Front Bearing and
01008
Front Bearing Plate.
11.
Remove front bearing shims and
01010
Spacer
Motor disassembly complete.
Housing Disassembly:
1.
Position housing in padded vise with air inlet facing up.
2.
Remove air fitting by securing
94523
Inlet Adapter with a wrench and twist air fitting from inlet adapter.
Important: 94523
Inlet Adapter must be secured before attempting to remove air fitting to avoid damaging valve body housing.
3.
Remove
94523
Inlet Adapter.
4.
Remove
95711
Retaining Ring from inlet adapter and separate
94521
Muffler Base from
94522
Muffler Cap. Remove
94528
Felt Muffler.
5.
Remove
01642
Air Control Ring from housing.
6.
Using a 2.5mm drift pin, tap
01017
Pin from housing and remove throttle lever assembly.
7.
Remove
95558
Retaining Ring using retaining ring pliers.
8.
Push
01247
Regulator from valve body housing and remove O-Rings.
Disassembly complete.
Motor Reassembly:
Important:
Be sure parts are clean and in good repair before reassembly
.
Follow all grease, oil, and torque specifications.
1.
Place
01148
Rotor in padded vise with spindle facing upwards.
2.
Slip
01010
Spacer onto
01148
Rotor.
3.
Place a .002" shim into
01008
Front Bearing Plate as an initial spacing and slip
01007
Bearing into plate.
Note: 01121
Shim Pak contains .001"
and .002" shims.
4.
Slip bearing/bearing plate assembly onto rotor, torque
51066
Rotor Nut onto rotor shaft.
5.
Check clearance between rotor and bearing plate by using a .001" feeler gauge. Clearance should be at .001" to .0015". Adjust clearance by repeating
steps 2-4 with different shim if necessary.
6.
Once proper rotor gap clearance is achieved, install well lubricated
01001
Blades (4) into rotor slots. Dynabrade recommends using their
95842
Air Lube.
7.
Install cylinder over rotor. Be sure air inlet holes of cylinder face away from
01008
Front Bearing Plate.
8.
Press
01015
Rear Bearing into
01245
Rear Bearing Plate. Press bearing/bearing plate assembly onto rotor. Be sure that pin and air inlet holes line up
with pin slot and air inlet holes in cylinder.
Important:
Fit must be snug between bearing plates and cylinder. If too tight, rotor will not turn freely. Rotor must then be lightly tapped at press fit end so
it will turn freely while still maintaining a snug fit. A loose fit will not achieve the proper preload of motor bearings.
10.
Secure motor housing in padded vise so motor cavity faces upwards. Install motor assembly into housing. Be sure motor inlet is facing the handle and it
drops all the way into housing
11.
Motor adjustment must now be checked. With motor housing still mounted in vise, pull end of rotor and twist (10-15 lbs. force), rotor should turn freely
without drag. If drag or rub is felt, then increase preload or remove shim. Also, push end of rotor and twist (10-15 lbs. force), rotor should turn freely
without drag. If drag or rub is felt, then deload or add shim.
12.
Install
95711
Retaining Ring onto
51066
Rotor Nut using retaining ring pliers, and slip
51072
Coupler on to motor assembly.
13.
Install
53550
Adapter into housing and torque 28 N•m/250 in. - lbs.
14.
Install
53552
Spindle and
51076
Spindle Cover onto housing to secure motor (torque 28 N•m/250 in. - lbs.).
Motor Reassembly Complete.
Valve Body Reassembly:
1.
Insert
01247
Speed Regulator Assembly with o-rings installed into housing. Secure with
95558
Retaining Ring.
2.
Secure valve body in vise with air inlet facing upwards.
3.
Insert
01464
Seal into housing.
4.
Line-up the hole in the
01477
Valve Stem with the hole in the housing (looking past brass bushing). Insert
01472
Tip Valve so that the metal pin passes
through the hole in the valve stem. Install
01468
Spring (small end first).
5.
Reassemble muffler assembly. Slip
94523
Inlet Adapter through muffler assembly and secure with
95711
Retaining Ring.
6.
Install air control ring into valve body housing.
(continued on next page)
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