Assembly Instructions -
(Continued)
Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires.
Please refer to parts breakdown for part identification.
12.
Press
02057
Bearing onto rotor and onto
51923
Rear Bearing Plate until it is seated.
Important:
Cylinder must fit snug between bearing
plates. If too tight, rotor will not turn freely. Rotor must be lightly tapped at press fit end until rotor spins freely while still maintaining a
snug fit. A loose fit will not achieve the proper preload on motor bearing.
(While pressing 02057 Bearing, make certain to contact inner race of bearing only.)
13.
Add one drop of Loctite
®
243 (or equiv.) to governor assembly male thread and screw governor assembly onto place (
LEFT HAND
thread) with a slotted screw head. Torque to 2 N•m (18 lb.-in.).
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.
Gear Casing Assembly:
1.
Install
54520
Bearing into front end of
53695
Gear Casing.
2.
Install gears with needle bearings and assemble onto planetary carrier by pressing retainer shafts into place.
3.
Place
96498
Wave Spring at the base of
53695
Gear Casing.
4.
Slide planetary carrier assembly into
53695
Gear Casing and through
54520
Bearing.
5.
Apply one drop of Loctite
®
to threads of
51935
Coupling and thread onto planetary carrier. Torque to 17 N•m (150 lb.-in.).
6.
Install ring gear over
54520
Front Motor Bearing, keeping 2 machined slots facing outward.
7.
Apply a small amount of Loctite
®
#567 to the male thread of the housing and thread
53695
Gear Casing over ring gear and onto housing.
Important:
Align rotor spline into planet gears to allow carrier to spin freely.
8.
When slots from ring gear line up with set screw hole. Apply a small amount of Loctite
®
#567 to
04014
Set Screw and install to lock ring gear in place.
9.
Torque
53695
Gear Casing to 35 N•m (310 lb.-in.).
10.
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˚.
11.
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.
12.
Press
54520
Bearing onto end of spindle that is closer to wrench flats.
Important:
While pressing
54520
Bearing, make certain to contact inner race of bearing only.
13.
Secure
51955
Extension 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.).
14.
On double bearing end, apply Loctite
®
#243 (or equiv.) to external threads and torque
50011
Collet Body to 17 N•m (150 lb.-in.).
15.
Install
51956
Felt Ring over
50011
Collet Body.
16.
Install
96512
Retaining Ring into groove inside
51952
Extension Handle.
17.
Insert spindle assembly, with
50011
Collet Body first, into larger diameter end of
51952
Extension Handle.
18.
Insert
51982
Bearing Spacer into larger diameter end of extension handle.
19.
Pull
51936
Coupling Insert half way off of
51935
Coupling.
20.
Apply small amount of Loctite
®
#567 (or equiv.) to external threads just above machined flats on
53695
Gear Casing.
21.
Align
51936
Coupling Insert onto
51935
Coupling
51952
Extension Handle.
22.
Thread gear casing/housing assembly onto extension handle.
23.
Secure front end of housing using
51989
Repair Collar (order separately) or a padded vise, align the vise jaws with machined flat on the silver ring.
Torque
51952
Extension Handle onto gear casing to 35 N•m (310 lb.-in.).
Gear Casing and Extension Assembly Complete.
Housing Assembly:
1.
Secure housing using
51989
Repair Collar,
(see back cover for Optional Accessories)
with collet 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
Vale Seat.
3.
Install
51944
Tip Valve.
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:
Before operating , place 2-3 drops of Dynabrade Air Lube (P/N
95842
) directly into inlet with throttle lever depressed. Operate tool for 30
seconds to allow air lube to properly lubricate internal motor components. Motor should now be tested for proper operation at 90 PSIG max. If tool operates
at a higher RPM than marked on the tool or if vibration and sound levels seem abnormal, the tool should be serviced to correct the cause before use.
Loctite
®
is a registered trademark of Loctite Corp.
