Dynabrade Dynabug 57860, User Manual

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Motor Assembly/Disassembly Instructions – Dynabug Orbital Sander
Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires.
A Motor Repair Kit (57098) is available which contains special tools for disassembly/assembly. Please refer to parts breakdown for part identification.
To Disassemble:
1. Disconnect tool from power source. Invert machine and secure in vice, using 57092 Collar (supplied in 57098 Repair Kit) or padded jaws.
2. Disconnect sanding pad by removing 96258 Screws (4) with a 3 mm wrench.
3. With a Phillips head screw driver remove 96114 Screws (6). Remove 96168 Screw with 3/16" hex wrench, and remove pad top from boot.
4. Disengage 96116 Clamp by using a screwdriver to unscrew clamp. Remove clamp, 57822 Boot and 57823 Pad Mount from housing.
5. Insert 56058 Lock Ring Tool (supplied in 57098 Repair Kit) into corresponding tabs of lock ring and unscrew. Motor may now be lifted out for service.
6. Remove rear ring from motor. Upper motor may now be disassembled. Remove 95626 Snap Ring.
7 Remove the rear plate and the cylinder assembly by securing the cylinder in a bearing separator gripped on the cylinder exhaust and extra pocket area.
Push the motor shaft balancer through the bearing.
8. Remove the rotor, vanes and rotor key from the motor shaft balancer. Remove the front plate using a (#2) arbor press. Support the edges of the
front plate while pressing on the small end of the motor shaft balancer.
9. a.) If, during step 9, the front plate and bearing remain together, press bearing out of the front plate using 57091 Press Tool (supplied in 57098 Repair Kit).
b.) If, during step 9, the front plate and 57088 Bearing remains on the motor shaft balancer, it can be removed with a bearing separator.
11. Remove 01206 Bearing from the rear plate by using a bearing press tool. Remove lock ring, washer and front ring.
12. Disassemble the balancer assembly as follows:
a.) Place motor shaft assembly into a soft jaw vise. Using a thin screwdriver, pick out the end of 95630 Snap Ring and peel out.
b.) Screw the threaded portion of the 56056 Bearing Puller (supplied in 57098 Repair Kit) into the 57069 Balancer Shaft and heat the outside of the
motor shaft balancer to approximately 200° F (approximately 10 seconds with a propane torch). Now, using the slider weight, pull the assembly out.
c.) Press off 56052 Bearing with a bearing separator and remove bearing seal and bearing shield.
13. If during step 12, the 56052 Bearing remains in the motor shaft balancer, it can be removed by heating the shaft balancer again and using either an
inside bearing puller or a blind hole bearing puller.
Tool disassembly complete.
To Assemble
Important: Be certain parts are clean and in good repair before assembling.
1. Assemble the balancer assembly as follows:
a.) Install 95630 Snap Ring onto 57069 Balancer Shaft. Install 95628 Shield with convex face toward hex of balancer shaft. Install 56053 Seal.
Note: Be certain seal is pressed completely over shaft step.
b.) Apply 1 drop of #271 Loctite ® (or equivalent) and spread over several places around the inside diameter of the 56052 Bearing and the outside
diameter of the 57069 Balancer Shaft.
c.) Press fit 56052 Bearing with seal side toward hex of balancer shaft up to shaft step. This must be a firm press fit for proper retention of bearing.
2. Place the motor shaft balancer in a soft jaw vise with large end-up.
3. Apply 1 drop of #271 Loctite ® (or equivalent) and spread over several places around the outside diameter of the 56052 Bearing and slide balancer
assembly into the motor shaft balancer until 56052 Bearing is firmly seated at bottom. Squeeze 95630 Snap Ring into groove in motor shaft balancer to
complete the assembly. Remove from vise.
4. Press 57088 Bearing onto the motor shaft balancer down to the shoulder. Place lock ring, washer and front ring on motor shaft balancer.
5. Press 57057 Front Bearing Plate onto 57088 Bearing and check for smooth rotation.
6. Place the 57090 Rotor and 56047 Rotor Key on the motor shaft balancer. Place the 56073 Vanes into the rotor slots.
Note: Vanes should be lightly lubricated with Dynabrade Air Lube P/N 95842 (or equivalent) before installation into the rotor slots.
7. Place 57058 Cylinder Assembly over rotor. The “short” line-up pin goes toward the front plate.
8. Place 57056 Rear Bearing Plate (with rear bearing pressed into place) over shaft and “long” end of line-up pin and press fit in place . Insert
95626 Snap Ring.
9. Place 57054 Rear Ring over the rear plate and line-up pin. Make sure that the “legs and fingers” on the front and rear rings line-up.
10. Secure motor housing in vise, using 57092 Collar or padded jaws. Spread 2-3 drops of pneumatic tool oil around the housing bore and slide motor
assembly in housing. Note: Be certain line-up pin enters the pocket in bottom of the housing and the “legs” of the rings stay in line.
11. Tighten lock ring with 56058 Lock Ring Tool torque to 28 N•m/250 in. - lbs.
12. Insert 57823 Pad Mount into boot. Attach boot to housing with exhaust hole facing back and slide clamp over boot.
13. Place 57837 Washer into hex pocket with shoulder down. Line-up holes in pad top with holes in boot and secure with 96114 Screws (6).
14. Secure pad top and boot to motor assembly by installing 57838 Washer, 95183 Washer and 96168 Screw through pad top and into balancer shaft.
15. Position pad top to desired angle and tighten clamp to 0.7 N•m/6 in. - lbs. so that the top of the clamp is even with the top of the boot.
16. Attach sanding pad by installing 96258 Screws (4).
Valve and Speed Regulator Assemblies:
1. Secure housing in vice using 57092 Collar or padded jaws. Remove inlet bushing, 01468 Spring, 01472 Tip Valve and 01464 Seal from housing.
2. Remove 95697 Snap Ring. Press the speed regulator and valve stem out of the housing. Remove the 01025 O-Rings (2).
3. Place new 01025 O-Rings (2) on the speed regulator and place in housing with valve stem. Install new 95967 Snap Ring.
4. Place seal in housing. Using tweezers or needle nose pliers, place the tip valve in the housing so that its pin goes into the valve stem hole. Place
01468 Spring into the housing so the small end is toward the tip valve.
5. Spread one drop of #567 Loctite ® (or equivalent) around the first threads of the first inlet bushing and tighten into housing torque to 23 N•m/200 in. - lbs.
Tool assembly is complete. Please allow 30 minutes for adhesives to cure before operating tool.
Loctite ® is a registered trademark of the Loctite Corp.
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