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Important: Manufacturers warranty is void if tool is disassembled before warranty expires.
A complete Tune-Up Kit, part number 96195, is available which includes assorted parts to help maintain motor in tip-top shape. These instructions are for use
in conjunction with Part Number 96283 Repair Kit, which includes special tools for proper disassembly/assembly of tool.
To Disassemble:
1. Disconnect tool from power source.
2. Invert machine and secure in soft jaw vise.
3. Remove sanding pad with 3 mm. hex wrench.
4. Remove counterbalance:
a.) Remove 95898 Screw with 5 mm. hex wrench. Note: To prevent counter balance rotation place a wrench on the counter balance.
b.) Remove counterbalance.
5. Pull out mounting plate sub-assembly.
6. Disassemble mounting plate sub-assembly:
a.) Remove 96276 Nuts (4) and 96274 Screws then lift out gear.
b.) Remove 96118 Screws (3).
c.) Press out 57335 Bearing by using 57091 Bearing Press Tool.
7. Remove 96166 Set Screw. Note: Remove 96150 Shims if so equipped.
8. Insert an adjustable spanner wrench or 96337 Lock Ring Wrench in the holes of the 57332 Lock Ring and turn counterclockwise to loosen. Motor may
now be lifted out for service.
9. Remove 95626 Retaining Ring from the motor shaft.
10. Attach a 2 in. bearing separator around the rear portion of the 54631 Cylinder nearest the rear bearing plate.
11. Place the separator on the table of a #2 arbor press with the larger end of the motor shaft pointing down.
12. Press the retaining ring end of the motor shaft out of the rear motor bearing by using a 3/16 in. flat nose punch.
13. Remove cylinder, rotor, blades and key.
14. Press the 57331 Shaft and 56052 Bearing out through the front end plate using a (#2) arbor press.
15. Secure the 57749 Pinion in a soft jaw (bronze or aluminum) vise. With the 96182 Front Plate Removal Tool and a 3/8" ratchet, or breaker bar, turn the
57324 Front End Plate counterclockwise to loosen.
16. Remove 01206 Bearing from 54629 Rear Bearing Plate. Press 56052 Bearing from 57331 Motor Shaft.
To Reassemble:
Important: Be certain parts are clean and in good repair before reassembling.
1. Use 57091 Press Tool and press 56052 Bearing onto 57331 Motor Shaft down to shoulder, seal side toward shoulder.
2. Apply 3 drops of #271 Loctite
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3. Place rotor key, rotor, and blades onto shaft. Note: Be certain rotor "floats" easily on the shaft. Because the design of this motor uses a "floating rotor",
there is no need to set or adjust gap between the rotor and end plates.
4. Place 54631 Cylinder over rotor. The "short" line-up pin goes toward the front plate.
5. Place rear bearing plate (with 01206 Rear Bearing pressed into place) over shaft and "long" end of line-up pin and press fit in place using
57091 Press Tool.
6. Install 95626 Retaining Ring, concave side toward motor. Note: Be certain retaining ring is completely pressed down into its groove on the shaft.
7. Grease the rubber seals inside the housing using a small amount of multi-purpose grease or petroleum jelly.
Note: Be curtain that rubber seals in housing have not pulled out of their seat during disassembly. If this has happened re-seat seals by pushing them
back in place until they are flush with inside diameter.
8. Slide motor assembly into housing. Note: With handle pointing down be certain line-up pin enters slot to the right of center.
9. Secure motor housing in a vice, using 57092 Collar or soft jaws (be careful not to over tighten tool in vise).
10. Tighten 57332 Lock Ring with 96337 Lock Ring Tool to 34.0 N•m/300 in. - lbs. Align holes in 57332 Lock Ring with hole in housing.
11. Apply a small amount of #242 loctite (or equivalent) to the threads of 96166 Set Screw. Use a 2 mm hex key and install set screw into the housing
through one of the holes in the lock ring until set screw is flush with the top of the lock ring.
12. Apply a bead of #242 Loctite
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to 34 N•m/300 in. - lbs. using 96181 Pinion Wrench.
13. Mounting Plate Sub-Assembly:
a.) Press 57335 Bearing into 57333 Mounting Plate.
b.) Insert 96118 Screws (3) and apply 1 drop of #271 Loctite
c.) Press 57748 Gear into 57333 Mounting Plate, making sure to align mounting holes and that the 96273 O-Ring on back of gear is in place before
assembly to mounting plate.
d.) Insert 96275 Washers into c-bore in gear.
e.) Apply 1 drop of #271 Loctite
Insert 96276 Nuts (4) and torque 7.0 N•m/60 in. - lbs.
14. Assemble mounting plate sub-assembly onto motor shaft machine assembly.
Note: If tool is equipped with 96150 Shim be sure to replace it on the shaft prior to reassembling the mounting plate onto shaft.
15. Assemble counterbalance to motor shaft.
16. Install 95898 Screw to secure counterbalance. Apply 1 drop of #242 Loctite
to 9.0 N•m/80 in. - lbs.). Note: To prevent counterbalance rotation with motor, use a wrench on the 57334 Counterbalance.
17. Attach sanding pad. Torque the 97010 Screws (5) to 3.38 N•m/30 in. - lbs.
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Motor Disassembly/Assembly Instructions
(or equivalent) to outside of bearing. Assemble front bearing plate onto shaft and press plate on outer race of bearing.
(or equivalent) to threads of 57324 Front Plate . Screw 57749 Pinion onto 57324 Front Plate and torque
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(or equivalent). Note: All screws should be hand tight before torque is applied.
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(or equivalent) to 96274 Screws (4), insert through gear and thread into mounting plate torque 7.0 N•m/60 in. - lbs.
(continued on page 4)
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(or equivalent) to threads and torque screws with 5 mm. hex wrench
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