Assembly Instructions
- (Continued)
Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires.
Please refer to parts breakdown for part identification.
13.
Using
96243
Bearing Press Tool (
ordered separately) press
02057
Bearing onto rotor and into
51923
Rear Bearing Plate hole 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. While pressing
02057
Bearing, make certain to contact inner race of bearing.
14.
Add one drop of Loctite
®
243 (or equiv.) to governor assembly male thread and screw governor assembly into place (
Left Hand Thread
) with slotted screw head.
Torque to 2 N•m (18 lb.-in.).
15.
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.
Motor Assembly Complete.
Right Angle Head Assembly:
1.
Press
01041
Gear Oil Fitting into
53649
Gear Oil Plate. Apply a drop of Loctite
®
#680 (or equiv) to the diameter of the gear oil plate and insert sub-assembly into right angle housing.
2.
Press
96325
Bearing into housing until it is firmly seated against
53649
Gear Oil Plate.
Important:
While pressing
96325
Bearing, make certain to contact outer race
of bearing only.
3.
Add one drop of Loctite
®
#243 (or equiv.) to male thread of
53635
Adapter and tighten pinion using a 3/16" Hex Key wrench and the pinion wrench flats.
Torque to 17 N•m (150 lb.- in.).
4.
Using
96244
Bearing Press Tool (
ordered separately) press
53635
Adapter into
01266
Bearing.
Important:
While pressing
01266
Bearing, make certain to contact inner
race of bearing only.
5.
Add one drop of Loctite
®
#243 (or equiv.) to male thread of adapter and tighten
51969
Coupling Nut using wrench flats. Torque to 17 N•m (150 lb.- in.).
6.
Insert sub-assembly into male threaded end of
53600
Right Angle Housing.
7.
Apply a small amount of Loctite
®
#567 (or equiv.) to
53600
Right Angle Housing thread, and install
53650
Lock Ring (
Left hand Threads
).
8.
Install
53665
Ring Gear over
54520
Front Motor Bearing, keeping 2 slots facing outward.
9.
Install gears with needle bearings and assemble onto planetary carrier by pressing retainer shafts into place.
10.
Place
96498
Wavy Washer at the base of
53695
Gear Casing female threaded end.
11.
Slide planetary carrier assembly, with threaded end first, into
53695
Gear Casing and through
54520
Bearing.
12.
Apply one drop of Loctite
®
#243 (or equiv.) to threads of
51969
Coupling Nut. Secure planetary carrier using
53698
Wrench (
order separately) and thread on
51935
Coupling
(twist clockwise). Torque to 17 N•m (150 lb.-in.).
13.
Apply a small amount of Loctite
®
#567 (or equiv.) to male thread of motor housing and thread
53695
Gear Casing over ring gear and onto motor housing.
Important:
Align
rotor spline into planet gears to allow carrier to spin freely.
14.
When slots from ring gear line up with set screw hole, apply a small amount of Loctite
®
#567 (or equiv.) to male thread of
04014
Set Screw, and install set screw to lock
ring gear in place.
15.
Torque
53695
Gear Casing to 35 N•m (310 lb.-in.).
16.
Place
50902
Coupling Insert into
51969
Coupling Nut. Make certain insert radii in coupling base, to correct alignment remove insert and rotate 90˚.
17.
Secure
53600
Right Angle Housing, against both side handle bosses, in a padded vise.
18.
Rotate motor housing/gear casing and
53650
Lock Ring until throttle lever is located between the 6-9 o'clock position. Throttle lever in this position safe guards against
accidental start ups of the tool. Torque lock ring to 35 N•m (310 lb.-in.).
19.
Place well lubricated
53608
Wick against
96325
Bearing with flat edge towards pinion gear. (Wick must be completely saturated with Dynabrade
95848
Gear Oil before
installation).
Note:
Do not contaminate wick with any other oil or grease product.
20.
Press
97679
Bearing onto spindle and against shoulder.
Important:
While pressing
97679
, make certain to contact inner race of bearing only.
21.
Press gear, with teeth facing away from bearing, into spindle and against
97679
Bearing inner race.
22.
Insert spindle assembly into
53600
Right Angle Housing until
97679
Bearing contacts housing shoulder.
23.
Rotate spindle while pressing down into housing to check for gear alignment and backlash. Install shims as required (minimum backlash is recommended for maximum
gear life. Make certain there is clarence throughout 360˚ revolution).
24.
Press
50899
Shaft Seal into
50963
Retainer with base of seal facing outward.
25.
Apply a small amount of Loctite
®
#567 (or equiv.) to the male thread of the retainer and thread into place. (
Left Hand Thread
)
26.
Using
97782
Pin Wrench (
ordered separately) or an adjustable pin wrench, torque retainer to 35 N•m (310 lb.-in.).
Housing Assembly:
1.
Secure housing using
51989
Repair Collar (
see back cover for Optional Accessories) with inlet facing upward.
2.
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.
3.
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 Seat.
4.
Install
51944
Tip Valve as shown.
5.
Pre-assemble muffler, slide
53683
Spacer over
53681
Inlet Bushing and up against the hex head base. Slide
94924
Wave Spring over
53681
Inlet Bushing and up against
spacer. Pre roll
94528
Felt and install it in
53686
Muffler Cap. Support felt in felt/muffler cap assembly and slide
53681
Inlet Bushing thru the inside until the muffler cap
assembly seats against the
94924
Wave Spring. Flare the felt and place
51940
Spacer over male thread and set
96442
O-Ring into groove at the base of thread. Return
felt to unflared form. Slide
51943
Spring into bushing and up to the two
51938
screens.
6.
Place
53682
Gasket over felt silencer and against
53686
Muffler Cap.
7.
Apply one drop of Loctite
®
#243 (or equiv.) to
53681
Inlet Bushing Thread.
8.
Align small inside diameter of
51943
Spring to cone point on
51944
Tip Valve and thread inlet bushing and sub-assembly into place. Torque bushing to 35 N•m (310 lb.- in.).
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 pinhole 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.
Orbital Head Assembly:
1.
Slide
61394
Switch Shaft into the housing so that it is in the rotary (unlock) position.
2.
Install
61935
Switch Spring,
61393
Pin,
61397
Spring, and
61396
Locking Pin Insert.
3.
Apply a small amount of the Loctite #242 (or equivalent) to the external threads of
61398
Locking Pin Bushing and install into the orbital head using the
96364
Slotted screwdriver.
4.
Wipe all oil and grease for the outside diameter of the
57069
Balancer Shaft with a clean cloth. Wipe all oil and grease from the inside diameter of the
56052
Bearing.
5.
Apply a small amount of the Loctite #609 (or equivalent) to the outside diameter of the
57069
Balancer Shaft.
6.
Place the
57069
Balancer Shaft on the tool plate of the
96232
#2 Arbor Press. Position the sealed side of the
56052
Bearing on the balancer shaft and use the
57091
Bear
Press Tool to install the bearing onto the balancer shaft.
7.
Wipe all oil and grease from the outside diameter of the
56052
Bearing and the bearing pocket of the orbital head. Apply a small amount of the Loctite #609 (or equivalent)
to the outside diameter of the bearing and install the balancer shaft and the bearing into the orbital head
8.
Apply a small amount of the Loctite #242 (or equivalent) to the threads of the three
95235
Screws and install these into the orbital head (Torque to 5.7 N•m/50lb-in.).
9.
Use the
95823
21mm Wrench to install the orbital head assembly on the spindle.
10.
Slide
61394
Switch Shaft to the lock position.
11.
Assemble the washers and spacer as shown on page 4 and place the backing pad on the
57069
Balancer Shaft. Use the
95823
21mm Wrench to hold the head stationary
while installing the
96168
Screw with a 3/16" hex key (Torque to 11.3 N•m/100lb-in.).
12.
Connect the polisher to the air supply hose and check for the proper operation.
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.
