Dynabrade 51604 Manual - Page 3

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Disassembly/Assembly Instructions - Sander / Polisher

Important: Manufacturer's warranty is void if tool is disassembled before warranty expires.

Please refer to parts breakdown for part identification.

Motor and Gear Casing Disassembly:

1. Important: inlet adapter must be secured before attempting to remove air fitting to avoid damaging composite motor housing.

2. Disconnect tool from power source, and secure motor housing, using the two molded flats, in a padded vise.

3. Remove 50970 Gear Casing Assembly using 40mm wrench flats provided.

4. Remove 04014 Set Screw from gear casing.

5. Push 50956 Hex Adapter through 50970 Gear Casing Assembly.

6. Remove 02552 Bearing from planetary assembly (opposite end from hex adapter).

7. Remove 53191 Ring Gear and spur gears from 53180 Planetary Carrier.

8. Secure planetary carrier in vise and remove 50956 Hex Adapter. Press carrier through 02552 Bearing.

9. Grab onto pinion gear and pull 53169 Motor Assembly from motor housing.

10. Secure 01028 Cylinder and press 04017 Rotor through 01721 Rear Bearing Plate.

11. Press 04017 Rotor through 53183 Front Bearing Plate and remove 01010 Spacer, 01007 Bearing and shims.

Motor Disassembly complete.

Motor Housing Disassembly:

1. Secure motor housing, using the two molded flats in a padded vise, with the air inlet facing upwards.

2. Remove 94519 Muffler assembly from motor housing.

3. Remove 01564 Air Control Ring, 01468 Spring, 01472 Tip Valve and 01464 Seal from motor housing.

4. Using a 2.5mm drift pin, tap 01017 Spring from housing and remove 01089 Throttle Lever and 01477 Valve Stem.

5. Remove 95558 Retaining Ring. Push 01247 Speed Regulator Assembly from housing.

Motor housing disassembly complete.

Right-Angle Housing and Spindle Disassembly:

1. Secure housing in a padded vise, and remove 50987 Lock Ring (left-hand thread) using 44mm wrench flats.

2. Remove 50951 Coupler and pull 53351 Coupling Nut and pinion assembly from housing.

3. Secure pinion in a padded vise and remove 53551 Coupling Nut, remove 01266 Bearing, 50986 Spacer and shims.

4. Secure 01266 Bearing and push 50985 Pinion Shaft through pinion and bearing, remove 50435 Key.

5. Secure housing in a padded vise with spindle facing upwards.

6. Remove 50963 Retainer using an adjustable pin wrench (left-hand thread).

7. Pull spindle assembly from angle-housing. Remove shims and 02048 Wick from housing.

8. Secure 50887 Bearing and push spindle through bevel gear and bearing.

9. Remove 96325 Shell Bearing using 57099 Bearing Puller.

Angle-Housing disassembly complete.

Motor and Gear Casing Reassembly:

Important: Be sure parts are clean and in good repair before reassembly. Follow all grease, oil, and torque specifications.

1. Place 04017 Rotor in padded vise with threaded spindle facing upwards.

2. Slip 01010 Spacer onto 04017 Rotor.

3. Place a .002" shim into 53183 Front Bearing Plate as an initial spacing and slip 01007 Bearing into plate. Note: 01121 Shim Pak contains .001"

and .002" shims.

4. Press bearing/bearing plate assembly onto rotor.

5. Check clearance between rotor and bearing plate by using a .001" feeler gauge. Clearance should be at .001" to .0015". Adjust clearance by repeating

steps 2-4 with different shim if necessary.

6. Once proper rotor gap clearance is achieved, install well lubricated 01185 Blades (4) into rotor slots. Dynabrade recommends using their 95842 Air Lube.

7. Install cylinder over rotor/pinion. Be sure air inlet holes of cylinder face away from 53183 Front Bearing Plate.

8. Press 02649 Rear Bearing into 01721 Rear Bearing Plate. Press bearing/bearing plate assembly onto rotor. Be sure that pin and air inlet holes line up

with pin slot and air inlet holes in cylinder.

Important: Fit must be snug between bearing plates and cylinder. If too tight, rotor will not turn freely. Rotor must then be lightly tapped at press fit end so

it will turn freely while still maintaining a snug fit. A loose fit will not achieve the proper preload of motor bearings.

10. Secure motor housing in padded vise so motor cavity faces upwards. Install motor assembly into housing. Be sure motor inlet is facing the handle and it

drops all the way into housing

11. Press front 02552 Bearing onto front end of 53180 Planetary Carrier.

12. Apply #271 Loctite® to 50956 Hex Adapter and install onto 53180 Planetary Carrier (torque 17.0 N•m/150 in. - lbs.).

13. Install 53193 Gears, 04026 Bearings and 53182 Gear Shafts onto planetary carrier.

14. Slip 53191 Ring Gear over gears and press rear 02552 Bearing onto planetary carrier.

15. Install planetary carrier assembly into 50970 Gear Casing by aligning the slot in 53191 Ring Gear with set screw hole.

16. Apply #567 Loctite (or equivalent) to 04014 Set Screw and install into 50970 Gear Casing.

17. Apply two drops of #271 Loctite adhesive to motor housing threads.

18. Install gear casing sub-assembly onto motor housing to secure motor, torque 28 N•m/250 in-lbs.