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Disassembly/Assembly Instructions - Wrenchless Pencil Grinder

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.

Notice: Special repair tooling referred to in these instructions can be ordered from Dynabrade.

DISCONNECT AIR SUPPLY BEFORE ANY MAINTENANCE OR SERVICE.

Collet Disassembly/Assembly Instructions

To Disassemble:

1. Rotate Lever 60083 counterclockwise and open collet.

2. To loosen and remove the collet insert, turn it counterclockwise.

To Assemble:

1. To reduce accessory run-out and sticking; thoroughly clean, inspect, and polish as necessary, the 60076/60108 Collet Insert, and the collet body end of the drive shaft.

2. Install an accessory with the correct diameter shank into the collet insert. Turn the collet insert clockwise to secure the accessory in the collet. Note: Tighten the collet insert

around the shank of the accessory until a precise slip fit is established.

3. Rotate the 60083 Lever clockwise until it locks, securing the accessory in the collet.

Motor Disassembly/Assembly Instructions

To Disassemble:

1. To remove the 60110/60067 Swivel Cover, place an adjustable pin spanner wrench in the exhaust holes of the swivel cover and turn it counterclockwise. Note: Moderate

heat may be necessary to soften the thread sealant.

2. To remove the 60099 Hex Nut, insert a 4 mm hex key into the internal hex recess in the turbine end of the drive shaft. Hold it stationary with the hex key and use an

adjustable wrench to remove the hex nut. Turn it counterclockwise.

3. Remove the 60069 Brake Plate, 51691/51675 Governor, and the 51678 Turbine.

4. Remove the 60068 Drive Shaft from the housing.

5. Remove the 60098 Pin and the 51656 Turbine Base.

To Assemble:

1. Install the 51656 Turbine Base onto the drive shaft.

2. Press the 60098 Pin into the cross-drilled hole in the drive shaft. Centralize the pin in the drive shaft.

3. Install the 51678 Turbine, and the 51691/51675 Governor onto the drive shaft.

4. To install the 60069 Brake Plate, align the slot in the brake plate with the 60098 Pin, and the notches with the 51678 Turbine.

5. Apply a small amount of Loctite #222 (or equivalent) to the hex nut threads on the drive shaft. Tighten the 60099 Hex Nut onto the drive shaft.

(Torque to 4.5 N•m/40 in. lbs.)

6. Install the drive shaft assembly into the housing.

7. Apply a small amount of the Loctite #567 (or equivalent) to the threads of the 60110/60067 Swivel Cover. Install the swivel cover onto the housing and tighten.

(Torque to 8.5 N•m/75 in. lbs.)

Motor Disassembly/Assembly Complete.

Bearing Replacement Instructions

(Use only Dynabrade specified replacement bearings.)

To Remove:

1. (Follow Collet Disassembly Instructions)

2. To replace the 60093 Bearing, and the 51651 Bearing, remove the 60066 Nose Piece. Turn it counterclockwise. Note: The 60081 Washer, 60102 Spring, and 60087

Washer Seal can be removed with the nose piece.

3. Remove the 60077 Bumper. Turn it counterclockwise.

4. Important: Note the orientation of the following parts as they are removed. These parts must be installed in the same manner as they are removed. – Carefully remove the;

60088 Front Seal, 60089 Outer Housing Seal, 60090 Inner Race Seal, and 60092 Rear Seal.

5. Remove the; 60107 Screw, 60082 Cam, 60083 Lever, and 60080 Cam Support from the housing.

6. Use an adjustable pin spanner wrench in the exhaust holes of the 60110/60067 Swivel Cover to remove it from the housing. Note: Moderate heat may be necessary to

soften the thread sealant.

7. Carefully remove the drive shaft with turbine air motor, the 51661 Wave Washer, the 60074 End Support, and the twenty [20] 60073 Spring Washers from the housing.

8. Remove the 60093 Bearing from the housing.

9. Use the 96346 Bearing Separator, and the 96232 Arbor Press [#2] to remove the 51651 Bearing from the drive shaft.

To Install:

1. Use the arbor press and the raised inside diameter of the 96418 Bearing Press Tool to install the 51651 Bearing onto the drive shaft.

2. If the 60074 End Support and/or 60073 Spring Washers [20] (conical shaped spring washers) have been separated from the drive shaft, they should be installed onto the

drive shaft at this point. Orient the two end conical shaped spring washers with their large diameter against the end supports. The remainder of the conical shaped spring

washers should be installed small diameter to small diameter, and large diameter to large diameter in alternating fashion. (See Detail B)

Note: Do not nest the 60073 Spring Washers.

3. Install the 51661 Wave Washer into the housing, and install the drive shaft and bearing. Be careful not to lose the end support and spring washer stack-up. Note: The

51651 Bearing should be a slip fit into the bore of the housing. If it is not a slip-fit, use very fine abrasive cloth to polish the bearing bore.

4. Rest the 60099 Hex Nut on the tool plate of the 96232 Arbor Press [#2] with the collet body end of the drive shaft pointing up. Place the 60093 Bearing over the collet body

end of the drive shaft so that it drops into the housing. Use the raised outside diameter of the 96419 Bearing Press Tool to install the bearing into the housing.

5. Install the; 60092 Rear Seal Washer, 60090 Inner Race Seal, 60089 Outer Housing Seal, 60088 Front Seal Washer.

6. Install the 60077 Bumper until it bottoms.

7. Install the; 60081 Washer, 60102 Flat Wire Compression Spring, 60087 Seal Washer so that they are properly positioned in the 60066 Nose Piece. (See Detail A)

8. Apply a small amount of the Loctite #567 (or equivalent) to the threads of the housing.

9. Install the nose piece with parts onto the housing. (Torque to 4.5 N•m/40 in. lbs.)

10. Apply a small amount of the Loctite #243 (or equivalent) to the threads of the 60107 Screw and install the 60082 Cam and 60083 Lever onto the housing.

11. Install the 60076/60108 Collet Insert, into the collet body end of the drive shaft. Note: Adjust the collet as stated in Collet Assembly Steps #2 & 3.

Bearing Replacement Instructions Complete.

Air Bushing Replacement (The 51662 Air Bushing should be replaced every time the tool is serviced.)

1. To replace the 51662 Air Bushing, use an Easy Out Screw Extractor, or another means to remove it from the swivel cover.

2. Carefully press a new 51662 Air Bushing into the swivel cover. Leave approximately 1/16" (1.5 mm) standing above the edge of the swivel cover. Join the swivel cover to

the housing, turning the cover until it bottoms against the housing. Next back the cover off slightly until the drive shaft rotates freely. Carefully connect the tool to the air

supply and depress the "ON" button. As the tool is running slowly tighten the swivel cover to 'wear-in' the air bushing. Once the swivel cover is bottomed against the

housing and the tool is running freely, depress the "OFF" button, wait for the drive shaft to stop, and disconnect the tool from the air supply. – Remove the swivel cover

from the housing. Apply a small amount of the Loctite #567 (or equivalent) to the threads of the 60110/60067 Swivel Cover. Join and tighten the swivel cover to the