Assembly Instructions -
(Continued)
Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires.
Please refer to parts breakdown for part identification.
14.
Install motor assembly into housing, making sure motor drops all the way into housing.
Note:
Align both
96445
Coiled Pins to slots in insert and against
51924
Gasket.
15.
Install
95438
O-Ring onto
53620
Adapter and slide adapter into housing and over
54520
Bearing.
16.
Place
96498
Wave Washer onto
53620
Adapter.
17.
Place
51936
Coupling Insert into
51935
Coupling. Make certain insert radii aligns with radii in coupling base, to correct alignment remove insert
and rotate 90˚.
18.
Press one
01007
bearing on end of
51955
Extension Spindle that is further from the wrench flats, then repeat with second
01007
Bearing on same
end of spindle.
Important:
While pressing
01007
Bearings, make certain to contact inner race of bearing only.
19.
Press
54520
Bearing onto end of spindle that is closer to wrench to wrench flats.
Important:
While pressing
54520
Bearing, make certain to contact inner race of bearing only.
20.
Secure spindle and apply Loctite
®
243 (or equiv.) to external threads then torque
51935
Coupling on single bearing end to 17 N•m (150 lb.-in.).
21.
On double bearing end, apply Loctite
®
243 (or equiv.) to external threads and torque spindle adapter to 17 N•m (150 lb.-in.).
22.
Install
51956
Felt Seal over spindle adapter.
23.
Install
96512
Retaining Ring into groove inside
51952
Extension Handle.
24.
Insert spindle assembly, with spindle adapter first, into larger diameter end of
51952
Extension Handle.
25.
Insert
51982
Bearing Spacer into larger diameter end of extension handle.
26.
Pull
51936
Coupling Insert half way off of
51935
Coupling to assure alignment with mating coupling.
27.
Apply adhesive Loctite
®
567 (or equiv.) to external threads on housing.
28.
Align
51936
Coupling insert onto
51935
Coupling in extension handle.
29.
Thread housing assembly onto extension handle.
30.
Secure front end of housing in a padded vise, align the vise jaws with machined flat on the silver ring.
31.
Apply wrench at wrench flats on
51952
Extension Handle and torque handle onto housing to 35 N•m (310 lb.-in.).
32.
Install guard onto extension housing.
Motor Assembly Complete.
Housing Assembly:
1.
Secure housing using
51989
Repair Collar (
see back cover for Optional Accessories
) with wheel adapter facing downward.
2.
Install
51945
Valve Seat by aligning 3 male prongs with three deep slots on insert. Make certain valve seat is pressed flat against base of pocket.
Note:
Add a few drops of Dynabrade Air Lube (P/N
95842
) to pocket walls before inserting
51945
Valve Seal.
3.
Install
51944
Tip Valve as shown.
4.
Slide
51942
Baffle into housing long end in first, and place
51941
Spring into shallow wall end of baffle.
5.
Pre-assemble
51937
Inlet Bushing by sliding
51939
Silencer Plate,
51940
Spacer over male thread and set
96442
O-Ring into groove at the base of
thread. Slide
51943
Spring into bushing and up to the two
51938
Screens.
6.
Apply one drop of Loctite
®
243 (or equiv.) to
51937
Inlet Bushing thread.
7.
Align small inside diameter of
51943
Spring to cone point on
51944
Tip Valve and thread
51937
Inlet Bushing and sub-assembly into place. Torque
bushing to 35 N•m (310 lb.-in.).
8.
Slide
96443
O-Ring onto
51946
Valve Stem and slide sub-assembly until o-ring passes through housing hole. Make certain valve stem assembly slides
freely after the o-ring passes through the hole.
9.
Remove housing from
51989
Repair Collar and place repair collar onto the bench top with the part number identifier against the bench. Align the
throttle lever holes to housing pin hole and rest the housing and throttle lever onto the legs of the repair collar. Press
96444
Coiled Pin into lever hole
and center into housing.
Tool Assembly Complete. Please allow 30 minutes for adhesives to cure before operating tool.
Important:
Motor should now be tested for proper operation at 90 PSIG max. If tool operates at higher RPM than marked on the tool of if vibration levels
seem abnormal, the tool should be serviced to correct the cause before use.
Loctite
®
is a registered trademark of Loctite Corp.
1.
Slide
51963
Backup Flange onto spindle adapter, align slot on backup flange with machined flats on spindle adapter.
2.
Slide abrasive wheel with blotters and
51694
flange washer onto spindle adapter, and install
96511
Hex Nut.
Caution:
Tighten hex nut only enough to prevent the abrasive wheel from spinning under working conditions. Over tightening the hex nut can cause
damage to the abrasive wheel and/or flanges.
Important:
Tool assembly should now be tested for proper operation at 90 PSIG max. If tool operates at higher RPM than marked on the tool of if vibration
levels seem abnormal, the tool should be serviced to correct the cause before use.
6
