Dynabrade 4657971919 User manual

Disassembly Instructions – Dynabug Sander
Important: Use these instructions along with the tool parts page or manual.
Notice: To avoid damage, use the special repair tools contained in the 57098 Motor Repair Kit.
Shut off the air supply and deplete air from the hose. Disconnect the tool from the air supply.
Motor Disassembly:
1. Position the 57092 Repair Collar around the housing.
Fasten the sander in a vise with the sanding pad facing up. Notice: Do not over tighten
the sander in the vise. Over tightening will make it difficult to remove the 57059 Lock
Ring. (SEE STEP #3)
Use a 3 mm hex key to remove the pad screws (4).
57092 Repair Collar
3 mm hex key

Use a 3/16" hex key to remove the 96168 Screw.
Use a Phillips screwdriver to remove the 96114 Screws (6).
Remove the 57825 Pad Top.
3/16" hex key

2. Use a slot-blade screwdriver to loosen the 96116 Clamp. Remove the clamp, 57822 Boot
and 57823 Pad Mount.
3. Use the 56058 Lock Ring Wrench to loosen the 57059 Lock Ring. Turn counterclockwise.

4. Pry-up, under the motor shaft balancer to remove the air motor from the housing.

Remove the 57054 Rear Ring from the inside of the housing.
5. Use retaining ring pliers to remove the 95626 Retaining Ring.

6. Fasten the 96346 Bearing Separator (2") around the 57058 Cylinder. Place the bearing
separator and motor in the 96232 Arbor Press (#2) with the counterweight pointing down.
Use the arbor press and a 5/16" or 8 mm diameter flat-end press tool to push the shaft
out of the 01206 Bearing.
7. Remove the rotor, vanes, key, and front bearing plate.
Use the bearing separator and the arbor press ram to remove the 57088 Bearing.
96346 Bearing Separator

8. By hand, or with the arbor press, use the 96214 Bearing Removal Tool to remove the 01206
Bearing from the 57056 Rear Bearing Plate.
9. Balancer Bearing and Shaft Disassembly:
a) Fasten the counterweight in a vise with aluminum or bronze jaws so that the hex of the
57069 Balancer Shaft is pointing up. Use a thin slot-blade screwdriver to pick-out the end
of the 95630 Snap Ring and remove the snap ring from the motor shaft balancer.
96214 Bearing Removal Tool

b) To break the adhesive bond, use two flat-blade screwdrivers (large) to pry-up on the
balancer shaft and bearing. Notice: If necessary, use a HEAT GUN to apply heat to
the counterweight.
Use the 56056 Bearing Puller to remove the balancer shaft and the 56052 Bearing.

c) Fasten the bearing separator between the 56052 Bearing and the hex end of the 57069
Balancer Shaft.
Place the bearing separator and the balancer shaft in the arbor press with the hex
end pointing down. Use the arbor press ram to break the adhesive bond.
Use a 5/16" or 8 mm diameter flat-end drive punch as a press tool to push the balancer
shaft out of the 56052 Bearing.
Remove the 59084 V-Seal.
Motor Disassembly Completed.
RAM

Clean and inspect all parts before assembling.
Assembly Instructions – Dynabug Sander
Motor Assembly:
1. Balancer Bearing and Shaft Assembly:

a) Install the 95630 Snap Ring around the 59084 V-Seal.
b) Install the 59084 V-Seal along with the 95630 Snap Ring onto the 57069 Balancer Shaft.
Place the flexible lip of the seal toward the hex end of the balancer shaft so that the flat
side is toward the 56052 Bearing.
c) Apply a small amount of Loctite #271 or equivalent to the outside diameter of the 57069
Balancer Shaft.
Loctite #271

d) Use the small diameter end of the 57091 Bearing Press Tool, and the 96232 Arbor Press
(#2) to install the 56052 Bearing (seal side toward hex). Press the bearing all the way
onto the balancer shaft until the bearing is tight against the step on the shaft.
57091 Bearing Press Tool

2. Apply a small amount of Loctite #271 or equivalent to the outside diameter of the 56052
Bearing. Install the balancer shaft with bearing into the bore of the motor shaft balancer.
Loctite
#271

3. Compress the 95630 Snap Ring into the groove in the motor shaft balancer.

4. Use the large diameter end of the 57091 Bearing Press Tool and the arbor press to install
the 57088 Bearing onto the motor shaft balancer.

IMPORTANT: For all models install the 57059 Lock Ring, 95973 Washer and 57055 Front Ring
onto the motor shaft balancer at this point.
57055 Front Ring
95975 Washer
57059 Lock Ring

5. Use the large diameter end of the 57091 Bearing Press Tool, and the arbor press to install
the 57057 Front Bearing Plate.
6. Install the 56047 Key and rotor onto the motor shaft balancer. The rotor should slide up and
down easily on the motor shaft.
56047 Key

7. Apply the 95842 Dynabrade Air Lube 10W/NR or equivalent to the vanes and install them
into the rotor.
8. If necessary, use the RAISED OUTSIDE DIAMETER of the 96244 Bearing Press Tool
and the arbor press to install the 01206 Bearing into the 57056 Rear Bearing Plate.
OIL
96244 Bearing Press Tool

9. Install the 57058 Cylinder so that the short line-up pin fits into the front bearing plate.
Use the arbor press ram to align and start the 01206 Bearing and rear bearing plate onto
the motor shaft.
10. Use the small diameter end of the 57091 Bearing Press Tool and the arbor press to install
the bearing/plate onto the motor shaft balancer. Notice: Carefully press the bearing and
plate down until it just touches the cylinder. This will establish a close fit between the
bearing plates and the cylinder.
JUST TOUCH