Dynabrade 10725 Quick Start Manual - Page 3

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Important: The manufactures warranty is void if the tool is disassembled before the warranty expires. Use these instructions in conjunction with the Part Number

57325 Tool Repair Kit. This kit includes special tooling for the proper disassembly/assembly of the Two-Hand Eight Inch Orbital Sander. This Tooling will be referred

to in these instructions. An air motor Tune-Up Kit, Part Number 98221 is also available. It contains the high and medium wear components that

most commonly need replacement.

Motor Disassembly:

1. Disconnect the sander from the air supply.

2. Use the 57092 Repair Collar to hold the sander in a vise. Position the sander so that the sanding pad is facing up. Note: Do not over tighten the collar and sander in the

vise. Only hold the sander snugly, so that the motor lock ring can be removed easily.

3. Use a 9/64" hex key wrench to remove the screws and sanding pad from the sander.

4. Use a 5/32" hex key wrench to remove the balance arm assembly by turning the hex key counterclockwise.

5. Remove the 56474 Balance Washer and 56470 Mount Plate Assembly.

6. Use the 56599 Lock Ring Tool to remove the 57332 Lock Ring by turning it counterclockwise.

7. Pull the air motor assembly out of the housing.

8. Use retaining ring pliers to remove the 95626 Retaining Ring.

9. Remove the 95911 O-Ring from the 56595 Cylinder and fasten a 2" bearing separator around the part of the cylinder that is closest to the 54629 Rear Bearing Plate.

10. Place the air motor with the bearing separator attached, onto the table of the 96232, #2 Arbor Press so that the balance end of the 56589 Shaft is pointing down.

11. Use a 5/16" dia. flat end drive punch as a press tool to push the shaft out of the 01206 Bearing. Use the 96213 Bearing Removal Tool to push the 01206 Bearing out of the

54629 Rear Bearing Plate. Note: This bearing removal tool is not included in the 57325 Repair Kit.

12. Remove the cylinder, rotor, vanes, and key.

13. Use the arbor press to push 56133 bearing and the 56589 Shaft out of the 56594 Front Bearing Plate.

14. Use a 2" bearing separator and arbor press to remove the 56133 Bearing from the 56589 Shaft.

Motor Disassembly Complete.

Motor Assembly:

Important: Clean and inspect all motor parts for wear or defect.

1. Install 56133 Bearing on the balance end of the 56589 Shaft.

2. Use the small end of the 57091 Bearing Press Tool and the 96232, #2 Arbor Press to push the 56133 Bearing onto the shaft until it fits against the

shaft step. (Drawing 1)

3. Use the large end of the 57091 Bearing press tool and the arbor press to install the front bearing plate onto the 56133 Bearing. (Drawing 2)

4. Install the 54673 Key so that the 90° side of the key fits into the keyway of the shaft and the tapered side of the key fits into the rotor. Install the 54705 Rotor/Blade Set (5)

onto the shaft.

5. Apply the 95842 Dynabrade Air Lube (10W/NR or equivalent) to the blades.

6. Install the 56595 Cylinder over the rotor so that the short line-up pin fits into the front bearing plate.

7. Place the 54629 Rear Bearing Plate over the shaft so that the long line-up pin fits through the hole in the rear bearing plate. (Drawing 3) Use the small end of the 57091

Bearing Press Tool to install the 01206 Bearing onto the shaft and into the 54629 Rear Bearing Plate. Use the press tool and the arbor press to install these so that there

is a snug fit between the bearing plates and the cylinder. Note: Carefully press the 01206 Bearing onto the shaft until it touches against the bearing seat on the inside of

the bearing plate. (Drawing 4)

8. Use retaining ring pliers to install the 95626 Retaining Ring so that the concave side of the ring is toward the motor assembly. Note: Be sure that the retaining ring is

completely pressed down into the groove on the shaft.

9. Use the 57092 Repair Collar to hold the housing in a vise so that the opening for the housing is facing up.

Note: Do not over tighten the collar and housing in the vise. Only hold the housing snugly, so that the motor and lock ring can be installed easily.

10. Apply a small amount of petroleum lubricant to the 95911 O-Ring and install the o-ring into the air inlet hole in the cylinder.

11. Install the motor assembly into the housing making sure to align the line-up pin with the line-up hole that is on the inside of the housing.

12. Install the 57332 Lock Ring onto the 56594 Front Bearing Plate so that the thread portion of the lock ring sits against the bearing plate. Use the 56599 Lock Ring Tool to

secure the motor in the housing. (Torque to 34 N·m/300 in. lbs.)

13. Install the appropriate shroud onto the housing.

14. Install the 56470 Mount Plate Assembly and the 56474 Balance Washer onto the 56589 Shaft. Apply a small amount of the Loctite #243 (or equivalent) to the I.D. threads

of the 56589 Shaft. Hold the balance arm assembly stationary with an adjustable wrench and use a 5/32" hex key to tighten the 96477 Screw by turning it clockwise.

(Torque to 9N·m/80 in. lbs.)

15. Use a 9/64" hex key wrench to install a weight-mated sanding pad.

Motor Assembly Complete.

Handle and Valve Disassembly:

1. Place the 57092 Repair Collar around the housing so that the handle is pointing up.

2. Use a Phillips screwdriver to remove the four screws that fasten the handle to the housing. Carefully pull the handle from the housing. This provides access to the tip

valve components, also the handle o-ring, gasket and vacuum plug.

3. Use a 1/8" dia. flat end drive punch to remove the 95627 Pin and the 56582 Safety Throttle Lever.

4. Pull the 56578 Speed Regulator and valve stem out of the housing.

Handle and Valve Disassembly Complete.

Handle and Valve Assembly:

1. Place the 57092 Repair Collar around the housing so that the handle mounting area is facing up.

2. Install the 01025 O-Rings (3) onto the 56578 Speed Regulator, apply a small amount of petroleum lubricant to the o-rings and insert the regulator assembly into the

housing. Note: Be careful that the o-rings do not get caught and pulled out of the o-ring grooves.

3. Install the 98459 O-Ring onto the 56579 Valve Stem, apply a small amount of petroleum lubricant to the o-ring and insert the shortest portion (from the end to the o-ring) of

the valve stem assembly into the speed regulator.

4. Install the 56582 Safety Throttle Lever onto the housing and secure it in place with the 95627 Pin.

5. Install the 56598 Seal into the air inlet passage of the housing.

Disassembly/Assembly Instructions

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