Disassembly/Assembly Instructions - Right Angle Sanders
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
96100
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 depress throttle lever to dissipate the remaining air. 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.
2.
Remove any abrasive product, flanging, guard, and side handle.
Motor Disassembly:
1.
Use a 3mm drive punch to remove the throttle lever.
2.
Roll back front edge of
25253
Insulating Cover just enough to expose wrench flats on
25257
Cup Nut.
3.
Place padding around the housing and carefully hold the housing stationary in a vise. Use an adjustable wrench or
98283
Open End Wrench (
sold separately
) to loosen the
25257
Cup Nut. Turn counterclockwise.
Note:
Applying heat to cup nut will help loosen adhesive.
4.
Carefully pull motor assembly out of the housing.
5.
Hold pinion gear in a vise with aluminum or bronze jaws. Use an adjustable wrench to remove the governor assembly.
LEFT HAND THREAD
Turn clockwise.
6.
Fasten
96346
2" Bearing Separator around the portion of
25235
Cylinder that is closest to
25237
Rear Bearing Plate. Place the bearing separator motor on the table
of the
96232
#2 Arbor Press with pinion gear pointing downward. Use a 3/16" or 4mm diameter flat end drive punch push rotor out of the
01206
Bearing.
7.
Remove the vanes from rotor and
01206
Bearing from bearing plate.
8.
Fasten the vane slot portion of rotor in a vise with aluminum or bronze jaws so that the pinion gear is pointing up.
9.
Use a hook/pin spanner wrench unthread pinion gear from rotor. Turn counterclockwise.
10.
Remove the front bearing plate, shims and
01010
Spacer.
Motor Disassembly Complete.
Spindle/Gear Disassembly:
1.
Place padding around the housing and carefully hold the housing stationary in a vise with the spindle pointing up. Use the
97782
Pin Wrench (
sold separately
) or an
adjustable pin wrench to remove
25265
Retainer.
LEFT HAND THREAD
Turn clockwise.
2.
Remove
53609
Felt Seal from spindle or retainer.
3.
Pull spindle and gear assembly out of the housing.
4.
Fasten the
96346
2" Bearing Separator under
02057
Bearing and press spindle through bearing. Remove
25264
Wick.
Remove
98243
Wave Spring from the right angle housing.
5.
Fasten the
96346
2" Bearing Separator between
01036
Bearing and spiral bevel gear. Place the bearing separator along with the spiral bevel gear assembly on the table of the
96232
#2 Arbor Press so that the spindle thread is pointing down. Push the gear off the spindle.
6.
Remove the
01036
Bearing the same way.
7.
Remove the housing from vise.
Spindle Disassembly Complete.
Spindle Lock Disassembly:
1.
Apply a small amount of the Dynabrade Air Lube 10W/NR (P/N
95842
or equivalent) around the
25273
Plunger Assembly.
2.
Place padding around the housing and carefully hold the housing stationary in a vise with the plunger assembly facing up.
3.
Use two flat blade screwdrivers to pry the plunger assembly out of the
25275
Spindle Lock Bushing.
4.
Remove the
98285
Spring and the
96156
Ring from the plunger.
Spindle Lock Disassembly Complete.
Valve Disassembly:
1.
Secure
25245
Throttle Handle in a vise using wrench flats so that the
25213
Inlet Bushing pointing upward.
2.
Use an adjustable wrench, unthread
25213
Inlet Bushing. Turn counterclockwise.
3.
Use needle nose pliers, pull
25249
Tip Valve from handle.
4.
Use a small screwdriver to remove the
96443
O-Ring from the valve stem and remove the valve stem.
5.
Position
25245
Throttle Handle in the vise with
25257
Cup Nut and
25256
Governor Housing pointing up. Use a 10 mm hex key to remove the
25256
and
25257
. Turn counterclockwise.
Note
: Applying heat to throttle handle will help loosen adhesive bond.
6.
Push the
51945
Valve Seat out of the
25245
Throttle Handle.
Valve Body Disassembly Complete.
Important: Clean and inspect all parts for wear before assembling. Note: Follow all lubricant, adhesive, and torque specifications.
Valve Assembly:
1.
Install
96443
O-Ring onto
25247
Valve Stem. Apply Dynabrade Air Lube to
96443
O-Ring and carefully install the valve stem and o-ring assembly into the
throttle handle.
Note
: Rotating the valve stem while inserting prevents damage to the o-ring
2.
Apply several drops of the Dynabrade Air Lube 10W/NR (P/N
95842
or equivalent) to valve seat pocket wall on the inside of the
25245
Throttle Handle before inserting the
51945
Valve Seat. Install the
51945
Valve Seat by aligning the 3 male prongs of the valve seat with three slots of the valve seat pocket in the throttle handle.
Note:
Use an
arbor press and the
96241
Bearing Press Tool to support the valve seat and press it into the valve seat pocket. Make certain that the valve seat lays flat.
3.
Use needle nose pliers install
25249
Tip Valve into the throttle handle.
4.
Install
51940
Spacer onto
25213
Inlet Bushing, followed by the
96442
O-Ring. Install the larger end of the
25250
Spring into the inlet bushing. The smaller end of the
spring fits against the back of the tip valve.
5.
Apply a small amount of the Loctite
®
#243 (or equivalent) to the external threads of the
25213
Inlet Bushing and install it onto the throttle handle. Secure throttle handle in a
vise using wrench flats. (Torque to 35N·m/310 lbs. in.)
6.
Position the throttle handle in vise with the inlet bushing pointing downward.
7.
Install the
66435
O-Ring onto the
25256
Governor Housing. Apply some Dynabrade Air Lube to the o-ring. Insert the governor housing through the
25257
Cup Nut. Apply a
small amount of the Loctite
®
#567 (or equivalent) to the external threads of the governor housing. Use a 10 mm hex key to fasten the governor housing and cup nut onto the
throttle handle. Turn clockwise. (Torque to 34N·m/300 lbs. in.)
Note:
The position of the throttle lever should be secured between the 9:00 to 11:00 o'clock position to best
protect the operator from unintentional starts.
8.
Apply a few drops of Loctite
®
#380 (or equivalent) to both sides of the throttle handle (as shown). Install the
25253
Insulating Cover and the
01462
Throttle Lever onto
the throttle handle.
Valve Assembly Complete.
(continued on next page)
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