Motor Assembly/Disassembly Instructions – 3" Dynabuffer
IMPORTANT: The Dynabrade Pneumatic Power Tool Lifetime Warranty Policy does NOT cover normally wearable parts and products. Before servicing this
tool please contact Dynabrade Inc. or a Dynabrade Subsidiary for information regarding the Dynabrade Pneumatic Power Tool Lifetime Warranty Policy. The
special repair tooling referred to in these instructions can be ordered from Dynabrade. (See Page 8)
Disconnect tool from the air supply before servicing.
Motor Disassembly:
1.
Use the
59293
Offset Wrench (26 mm) to remove the back-up pad.
2.
Install the
95492
Screws (part of
96519
Tool Repair Kit) into the two handle bosses in the
55160
Housing.
3.
With the shaft balancer (counterbalance) facing up, position
95492
Screws between the vise jaws and secure the
55126
3" Dynabuffer in the vise.
NOTICE: Do not over tighten the vise.
4.
Use the
95050
Hex Key (5/64") to remove the four
97101
Screws from the
55157
Inner Shroud.
5.
Use the
56058
Lock Ring Wrench to loosen the
55154
Lock Ring. Turn counterclockwise.
6.
Loosen the vise and pull the motor assembly out of the
55160
Housing. Use the
96343
Retaining Ring Pliers to remove the
95626
Retaining Ring.
7.
Fasten the
96346
Bearing Separator between the
54679
Rear Bearing Plate and the
55151
Cylinder Assembly.
8.
With the bearing separator secured to the motor assembly, place the separator on the table of the
96232
Arbor Press (#2) with the counterbalance pointing down.
9.
Use a 5/16" diameter flat end drive punch as a press tool and push the
55153
Shaft Balancer out of the
01206
Bearing.
10.
Remove the rotor, vanes, and the
54673
Key from the shaft balancer.
11.
Remove the
55152
Front Bearing Plate from the
02695
Bearing.
12.
Fasten the bearing separator between the counterbalance and the
02695
Bearing. Use the arbor press to remove the bearing.
13.
Secure the counterbalance of the
55153
Shaft Balancer in a vise with aluminum or bronze jaws so that the 26 mm hex end of the
57069
Balancer Shaft is
accessible and facing up.
14.
Use a small thin screwdriver to pick the notched end of the
95630
Snap Ring out of the shaft balancer. Work the screwdriver under and around the
95630
Snap Ring
to remove it.
15.
Apply heat to the counterbalance with a HEAT GUN. Use the
56056
Bearing Puller to remove the
57069
Balancer Shaft and
56052
Bearing.
16.
Fasten the bearing separator between the 26 mm hex end of the
57069
Balancer Shaft and the
56052
Bearing. Place the separator on the table of the arbor press
with the hex end of the balancer shaft pointing down. Use a 5/16" diameter flat end punch as a press tool and push the
57069
Balancer Shaft out of
the
56052
Bearing.
Motor Disassembly Complete.
Shroud Disassembly:
NOTICE: Use the 95050 Hex Key (5/64") to remove the four 97101 Screws from the 55157 Inner Shroud before removing the motor from the 55160
Housing. The motor must be removed from the 55160 Housing, before the shroud assembly can be removed.
1.
Install the
95492
Screws into the two handle bosses in the
55160
Housing.
2.
With the shroud facing up, position
95492
Screws between the vise jaws and secure the
55160
Housing in the vise.
NOTICE: Do not over tighten the vise.
3.
Gasp the shroud assembly and carefully pull it from the
55160
Housing.
4.
Rotate the
55157
Inner Shroud to release it from the
55156
Outer Shroud. Separate the two shrouds and remove the
55158
Muffler Insert.
5.
Remove the two
55161
O-Rings from the inner and outer shrouds.
6.
Remove the
97166
Hang Plate from the
55160
Housing.
Shroud Disassembly Complete.
Throttle Body Disassembly:
1.
Install the
95492
Screws into the two handle bosses in the
55160
Housing.
2.
With the air inlet pointing up, position
95492
Screws between the vise jaws and secure the
55160
Housing in the vise
NOTICE: Do not over tighten the vise.
3.
Slide back the
01547
Collar onto the
45206
Housing Sleeve. Use a “Wide-Open” smooth jaw adjustable, or a 34 mm open-end wrench to loosen and remove the
throttle body from the
55160
Housing. NOTICE: LEFT HAND THREAD, Turn clockwise.
4.
Pull the
45267
Insert out of the
45252
Throttle Body Housing.
5.
Remove the
45277
Filter Cage and the
45278
Filter from the inside of the throttle body housing.
6.
Insert the hex end of the
96402
Special Repair Tool into the hex socket in the bottom of the housing.
With the air inlet adapter pointing up, secure the wrench flats of the
96402
Special Repair Tool in a vise with aluminum or bronze jaws. Use two wrenches when
removing the air connection fitting. Place one wrench on the
55168
Inlet Adapter to hold it stationary, and use another wrench to remove the air fitting. Use an
adjustable wrench to remove the
55170
Flow Control Assembly from the throttle body. NOTICE: Refer to the exploded view of the speed control assembly to identify
the parts and their proper order of assembly.
7.
Use needle nose pliers to remove the
01468
Spring, and the
58365
Tip Valve. Use a small screwdriver to remove the two
01464
Valve Seals.
8.
Use a 3/32" diameter flat end drive punch to remove the
97060
Pin and
45263
Throttle Lever Assembly.
9.
Remove
97045
Plunger.
10.
Use a slot blade screwdriver to remove the
45257
Throttle Bushing.
11.
Push the
45252
Throttle Body Housing out of the
45206
Housing Sleeve.
Throttle Body Disassembly Complete.
Important: Clean and inspect all parts before assembling.
Throttle Body Assembly:
1.
Insert the hex end of the
96402
Special Repair Tool into the hex socket in the bottom of the
45252
Throttle Body Housing.
2.
With the air inlet opening pointing up, secure the wrench flats of the
96402
Special Repair Tool in a vise with aluminum or bronze jaws.
3.
Install the
45206
Housing Sleeve onto the
45252
Throttle Body Housing.
4.
Use a slot blade screwdriver to install the
45257
Throttle Bushing.
5.
Install
97045
Plunger.
6.
Install the
45263
Throttle Lever Assembly and secure it with the
97060
Pin. Install the two
01464
Valve Seals. Use needle nose pliers to install the
58365
Tip Valve,
and the
01468
Spring.
5
(continued on next page)
96402 - Special Repair Tool
“Tear-Drop End”
Hex End
