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Assembly/Disassembly Instructions - Continued

7. Position the end of the 18594 Pinion Gear on the tool plate of the arbor press and place the rear bearing/plate assembly on the rear bearing journal of

the rotor. Note: Make sure that the cylinder line-up pin 18572 aligns with the hole in the rear bearing plate.

8. Use the raised inner portion of the 96240 Bearing Press Tool and the arbor press to push the 18555 Bearing along with the rear bearing plate down onto

the rotor until the bearing plate touches the cylinder. This should create a snug fit between the bearing plates and the cylinder. If the fit is too loose, add

a slight bit more press (preload). Note: A "snug" fit allows the cylinder to be shifted back and forth with a small amount of finger pressure. However, the

fit should not be loose or sloppy.

9. Use the 96343 Retaining Ring Pliers to install the 18567 Retaining Ring onto the rotor.

10. Hold the 18552 Housing in a vise with bronze or aluminum jaws so that the motor opening is pointing up.

11. With the bearing plates and the cylinder aligned, apply a film of oil to the outside diameter of the motor. Orient the motor according to the exhaust

passage in the 18552 housing and the 18579 Valve Housing. Carefully slide the motor into the 18552 Housing. Note: It may be necessary, warm the

housing with a "Hot Air Gun". This will expand the housing and facilitate the installation of the motor.

12. Install the 18576 Gasket, 18577 Spacer and 18578 Gasket. These must align with the 18572 Pin, air inlet and exhaust openings.

13. Orient and install the 18579 Valve Housing so that the air inlet and exhaust openings align correctly.

14. Use the 95331 (4mm) Hex Key to fasten the valve housing to the 18552 Housing with the 18559 Washers (4) and the 18580 Screws (4).

(Torque to 10.75 N•m/95 in. lbs.)

15. Install the 18601 Grip onto the 18579 Valve Housing. Note: A "Hot Air Gun" can be used to warm the 18601 Grip, making it more flexible.

16. Install an air fitting into the 18591 Inlet Bushing and connect to the air supply. Test the air motor for proper operation.

Motor Assembly Complete.

Right Angle Gear Assembly:

1. Wipe off the surface of the 96231 Tool Plate to make sure that it is clean. Place the open side of the 18561 Bearing on the tool plate so that the inner

race is supported. Position the spindle into the bearing so that the threaded end is pointing up. Press the spindle and the bearing together.

2. Place the 18902 Spindle Cap on the tool plate so that the open side of the bearing pocket is facing up.

3. Position the spindle with the bearing on the spindle cap so that the threaded end of the spindle is pointing up. Press the spindle with bearing all the way

into the spindle cap.

4. Use the 96343 Retaining Ring Pliers to install the 18562 Retaining Ring.

5. Clean the keyway of the spindle with a swab moistened with acetone. Also, clean the 18563 Key with acetone and apply a small amount of

Loctite

#380 (or equivalent) to the keyway. Install the key and let the adhesive set.

6. Install and press the 18593 Bevel Gear onto the spindle. Apply a small amount of the 95542 Grease to the bevel gear and pinion.

7. Install the 18557 Wave Washer and use the retaining ring pliers to install the 18556 Retaining Ring.

8. Place the threaded portion of the spindle on the tool plate of the arbor press and use the raised center portion of the 96240 Bearing Press Tool

to press the 18555 Bearing onto the spindle.

9. Install the 18554 Spacer into the 18552 Housing so that the raised outer portion of the spacer will be against the outer race of the 18555 Bearing.

10. Orient the air bleed notch of the spindle cap toward the throttle lever and install the spindle assembly into the housing. Check the fit of the gears and

for smooth rotation.

11. Use the 95331 (4mm) Hex Key to install the 18560 Screws (4), and 18559 Washers (4). (Torque to 9 N•m/80 in. lbs.)

12. Apply 3 plunges of the 95542 Grease through the grease fitting with the 95541 Lubrication Gun initially, and after every 100-hour interval of use.

Right Angle Gear Assembly Complete.

Orbital Head Assembly:

1. Wipe all oil and grease from 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.

2. Apply a small amount of the Loctite

3. 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 Bearing Press Tool to install the bearing onto the balancer shaft.

4. 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.

5. Apply a small amount of the Loctite

(Torque to 5.7 N•m/50 in. lbs.)

6. Use the 95823 21mm Wrench to install the orbital head assembly onto the spindle.

7. Install the backing pad by using the 50679 26mm Wrench, assemble washers and spacer as shown on page 4. Insert the wrench in between the

backing pad and the orbital head to hold the 57069 Balancer Shaft stationary while installing the 96168 Screw with a 3/16" hex key.

(Torque to 11.3 N•m/100 in. lbs.)

8. Connect the polisher to the air supply hose and check for the proper operation.

Orbital Head Assembly Complete. Polisher Assembly Complete. Please allow 30 minutes for adhesives to cure before operating tool.

Important: Motor should now be tested for proper operation at 90 PSIG. If motor does not operate properly or operates at a higher RPM than marked on the

tool, the tool should be serviced to correct the cause before use. Before operating, place 2-3 drops of Dynabrade Air Lube (P/N 95842) directly into air inlet

with throttle lever depressed. Operate tool for 30 seconds to determine if tool is operating properly and to allow lubricating oils to properly permeate motor.

Right Angle Gear Lubrication Instructions:

• Apply 3 plunges of the 95542 Grease through the grease fitting with the 95541 Lubrication Gun after every 100-hour interval of use.

Loctite

is a registered trademark of Loctite Corp.

#609 (or equivalent) to the outside diameter of the 57069 Balancer Shaft.

#242 (or equivalent) to the threads of the three 95235 Screws and install these into the orbital head.