Dynabrade 58503 Safety, Operation And Maintenance - Page 5

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Disassembly/Assembly Instructions – Dynabug II Sander

Important: Manufacturers warranty is void if the tool is disassembled before the warranty expires.

The Tool Repair Kit 57874 is available. This kit includes: 56058 Lock Ring Tool, 57092 Repair Collar, 57091 Bearing Press Tool, 95266 (3mm) Hex Key and 96034

(12mm) Hex Key. These will assist in the disassembly and assembly of the Dynabug II Orbital Sander. Please refer to the parts breakdown list for the proper

part number identification.

Disassembly:

1. Close off the air supply and disconnect the sander from the air supply line.

2. Place the 57092 Repair Collar around the housing and secure the sander in a vise so that the pad and/or pad base are facing up. Note: Do not over tighten the sander in

the vise, as this will make the removal of the 56046 Lock Ring and the motor difficult.

3. Use a Phillips Screwdriver to remove the (4) 96539 Screws, (4) 96538 Washers and sanding pad.

4. Insert a 3/16" dia. drive punch through one of the holes in the 57895 Pad Base to prevent the shaft balancer from rotating. Use the 95266, (3mm) Hex Key to remove the

95344 Screw along with the 95935 Washer by turning it counterclockwise.

5. For vacuum models refer to the Vacuum Conversion Instructions on page 6 and diagrams on page 8, then remove the vacuum components.

6. Position two flat blade screwdrivers between the counterweight and the bearing area of the pad base. Pry the pad base away from the housing.

7. Use the small end of the 57091 Bearing Press Tool along with the 96232 (#2) Arbor Press to remove the 54520 Bearing from the pad base.

8. Use the 56058 Lock Ring Tool to loosen the 56046 Lock Ring by turning it counterclockwise.

9. Remove the 57896 Felt Seal from the shaft balancer and pull the motor out of the housing. Remove the 01024 O-Ring from the cylinder.

10. Use retaining ring pliers to remove the 98463 Retaining Ring.

11. Fasten the 96236 (2") Bearing Separator around the part of the 59051 Cylinder that is closest to the 59077 Rear Bearing Plate.

12. Place the bearing separator on the table of the arbor press so that the counterweight is pointing down and use a 1/4" dia. flat end drive punch to push the shaft balancer

out of the 58368 Bearing. Note: If it's necessary, the 58368 Bearing can be removed from the bearing plate with the 96214 Bearing Removal Tool and the arbor press.

13. Remove the rotor, blades, and key.

14. Use the arbor press to push the shaft balancer, the 59083 Felt Washer, and the 58368 Bearing out of the 59076 Front Bearing Plate.

15. Remove the lock ring and the 59057 Seal.

16. Use the bearing separator and the arbor press to remove the 58368 Bearing and the felt washer from the shaft balancer.

Motor Disassembly Complete.

Valve Disassembly:

1. Use a 2.5mm drive pin punch to remove the 98927 Pin and the 57888 Throttle Lever.

2. Remove the 01494 Inlet Bushing by turning it counterclockwise.

3. Remove the spring, tip valve, and seal.

4. Use retaining ring pliers to remove the 95697 Retaining Ring and push the 59075 Speed Regulator out of the housing.

5. Remove the valve stem and the o-rings from the speed regulator.

Valve Disassembly Complete.

Important: Clean and inspect all parts for wear or defect before assembling sander.

Assembly:

1. Install the 56046 Lock Ring onto the 57892 Shaft Balancer so that the side marked 'OFF' is toward the counterweight.

2. Install the 59083 Felt Washer into the 59057 Seal and place these onto the shaft balancer. (See Drawing 1)

3. Use the small end of the 57091 Bearing Press Tool along with the arbor press to install the 58368 Bearing onto the shaft balancer. (See Drawing 2)

Note: Be certain that the felt washer does not get pinched between the bearing and the shaft balancer.

4. Use the large end of the 57091 Bearing Press Tool to install the 59076 Front Bearing Plate onto the 58368 Bearing. (See Drawing 3)

Note: Pull the 59057 Seal up tight against the 59076 Front Bearing Plate.

5. Install the 56047 Key and the 57113 Rotor/blades (5) onto the shaft balancer. Note: These should be lubricated with the 95842 Dynabrade Air Lube

(10W/NR or equivalent).

6. Install the 59051 Cylinder so that the short line-up pin fits to the front bearing plate.

7. Install the 58368 Bearing into the 59077 Rear Bearing Plate.

8. Align the cylinder line-up pin with the hole in the rear bearing plate. Use the small end of the 57091 Bearing Press Tool along with the arbor press to install the

bearing/plate onto the shaft balancer as is shown in Drawing 4. Press the bearing/plate down until it touches the cylinder. This should create a snug fit between the

bearing plates and the cylinder.

9. Install the 98463 Retaining Ring onto the shaft balancer and compress the ring into the groove on the shaft.

10. Install the 01024 O-Ring into the cylinder and apply a small amount of the Dynabrade Air Lube onto the o-ring.

11. MARK the edge of the housing motor opening to identify the location of the line-up notch on the inside of the housing.

12. Align the cylinder line-up pin with the 'NOTCH LOCATION MARK' and install the motor into the housing. Note: Be certain that the line-up pin enters the notch

in the housing.

13. Use the 57092 Repair Collar to carefully hold the tool in a vise so that the counterweight is pointing up.

14. Use the 56058 Lock Ring Tool to tighten the 56046 Lock Ring by turning it clockwise. (Torque to 17 N·/150 in.-lbs.) Note: Apply a slight amount of pressure down onto

the lock ring while turning the lock ring tool counterclockwise. The lock ring should find the thread. Secure the lock ring by turning it clockwise.

15. Install the 57896 Felt Seal onto the shaft balancer.

16. For vacuum models refer to the Vacuum Conversion Instructions on page 6 and diagrams on page 8, install the vacuum components.

17. Apply a small amount of the Loctite #271 (or equivalent) in two places on the inside of the pad base bearing pocket. Place the 57895 Pad Base on the tool plate of the

arbor press so that the bearing pocket is facing up. Use the flat face of the arbor ram to push the 54520 Bearing into the pad base until the bearing is flush with the

surface of the pad base.

18. Use the arbor press and the small end of the 57091 Bearing Press Tool to carefully install the pad base with the bearing onto the shaft balancer. Align the (4) 57890

Isolator Post with the 4 mounting holes in the pad base.

19. Insert a 3/16" dia. drive punch through one of the holes in the pad base to prevent the shaft balancer from rotating. Apply a small amount of the Loctite #243 (or equivalent)

to the internal threads of the 57892 Shaft Balancer and install the 95344 Screw along with the 95935 Washer. (Torque to 5.0 N·m/45 in. lbs.)

20. Use a Phillips Screwdriver to install the (4) 96539 Screws, (4) 96538 Washers and sanding pad. Note: When installing a vacuum pad orient the open oval pocket in the

pad toward the back of the sander so that it will align with the vacuum tube.

Motor Assembly Complete.