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Dynabrade Grinder Series Disassembly And Assembly Instructions

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Disassembly, Assembly Instructions - 2.8 hp Grinder/Sander Series:
Ø 7" & 9", Right Angle
Models: Use for all models.
Important: Disconnect from the air supply.
Notice: Use these instructions along with the specific tool manual for each model.
To avoid damage, use the proper repair tools designed for motor disassembly and
assembly.
Ÿ Remove any flanges, abrasive, back-up disc or guard.
Motor Disassembly: (Tutorial shows tool with 54951 Spindle. - Applies to all models.)
1. Fasten housing in vise (bronze or aluminum jaws) with throttle handle pointing up.
• Use a 4mm hex key to remove 95720 Screws (4). Turn counterclockwise.

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Summary of Contents for Dynabrade Grinder Series

  • Page 1 Disassembly, Assembly Instructions - 2.8 hp Grinder/Sander Series: Ø 7" & 9", Right Angle Models: Use for all models. Important: Disconnect from the air supply. Notice: Use these instructions along with the specific tool manual for each model. To avoid damage, use the proper repair tools designed for motor disassembly and assembly.
  • Page 2 54961 Spacer 54960 Motor Spring 54958 Gasket 2. Remove throttle handle assembly. Ÿ Remove 54961 Spacer, 54960 Motor Spring, and 54958 Gasket.
  • Page 3 3. Remove 54953 Governor Chamber.
  • Page 4 4. Use soft-faced hammer to knock motor assembly loose from housing and remove.
  • Page 5 5. Carefully, fasten pinion gear in vise (bronze or aluminum jaws). Ÿ Use a slot-blade screwdriver to remove governor assembly. Turn clockwise. Left Hand Thread...
  • Page 6 96346 Bearing Separator 96232 Arbor Press 6. Fasten 96346 Bearing Separator (2") around 54905 Cylinder. Place separator and motor in 96232 Arbor Press (#2) with pinion gear pointing down. Ÿ Use a Ø " flat-end drive punch to push rotor out of 54907 Bearing. ⅛...
  • Page 7 7. Use external ring pliers to remove 54907 Bearing from 54880 Rear End Plate.
  • Page 8 8. Remove 54904 Vanes from 54903 Rotor.
  • Page 9 14MM 9. Use 95262 Wrench (14mm) to remove pinion gear. Turn counterclockwise.
  • Page 10 10. Remove; 54900 Bearing, 54901 Front End Plate along with shims and 54902 Spacer. Motor disassembly completed. Clean and inspect parts. Replace all parts that are worn or damaged.
  • Page 11 Motor Assembly: 1. Fasten 54903 Rotor in vise (bronze or aluminum jaws), with spindle pointing up. Ÿ Install 54902 Spacer onto rotor.
  • Page 12 Shims 54900 Bearing 54909 Shim 01787 O-Ring 2. Install 54909 Shim into 54901 Front End Plate. Ÿ Select .003" (~0.08 shim thickness from 94910 Shim Pack and install into front end plate. Ÿ Install 01787 O- Ring into outside diameter groove of plate. Ÿ...
  • Page 13 Loctite #243 3. Install bearing and plate onto rotor. Ÿ Apply a small amount of Loctite #243 to spindle threads of rotor.
  • Page 14 Torque to: 17 N•m/~150 lbs. in. 14mm Use 14mm Wrench (or thin crowfoot) to fasten pinion gear. Turn clockwise. Ÿ Torque to: 17 N•m/~150 lbs. in.
  • Page 15 .001"-.0015" (~0.03-0.04 mm) 5. Carefully, fasten pinion gear in vise (bronze or aluminum jaws). Push the front-end plate away from the rotor. Check clearance between the rotor and plate. Ÿ Use a .001" (~0.03 mm) thick feeler gauge. Ÿ Notice: The clearance should be .001"-.0015" (~0.03 to ~0.04 mm). Ÿ...
  • Page 16 6. Apply 95842 Dynabrade Air Lube 10W/NR or equivalent to 54904 Vanes and install.
  • Page 17 7. Install 54905 Cylinder and rear end plate so that air inlet openings line up.
  • Page 18 54880 Rear End Plate 96773 O-Ring 96772 Wave Washer 96779 O-Ring 8. Install 54880 Rear End Plate with related components. • Position 54907 Bearing on assembly.
  • Page 19 96419 9. Use the RAISED INSIDE DIAMETER of 96419 Bearing Press Tool, and the arbor press to install rear bearing. Ÿ Press bearing flush with top of plate. This will produce ~12 Lbs. load between both bearing plates and the cylinder.
  • Page 20 Left Hand Thread. Turn counterclockwise. Torque to: 1.4 N•m/~12 lbs. in. 54998 Governor Assembly #243 Loctite 10. Carefully, fasten pinion gear in vise (bronze or aluminum jaws). • Apply a small amount of Loctite #243 to threads of governor. • Use a slot-blade torque-driver to install governor assembly. •...
  • Page 21 Motor Installation: 95526 O-Ring Governor Chamber Motor Assembly 1. Fasten housing in vise (bronze or aluminum jaws). Ÿ Carefully slide motor assembly into housing. Ÿ Install 54953 Governor Chamber with 95526 O-Ring.
  • Page 22 54961 Spacer 54960 Motor Spring 54958 Gasket 2. Install 54958 Gasket, 54960 Motor Spring, 54961 Spacer. Ÿ Install throttle handle assembly and 95720 Screws (4).
  • Page 23 Torque to 9 N•m/~80 lbs. in. 3. Use a 4mm hex key to fasten 95720 Screws (4). Turn clockwise. Ÿ Torque to 9 N•m/~80 lbs. in. Motor installation completed.
  • Page 24 Disassembly, Assembly Instructions - 2.8 hp Grinder/Sander Series: Ø 7" & 9", Right Angle Models: Use for all models. Important: Disconnect from the air supply. Notice: Use these instructions along with the specific tool manual for each model. To avoid damage, use the proper repair tools designed for motor disassembly and assembly.
  • Page 25 2. Remove work spindle assembly from housing.
  • Page 26 3. Use tweezers to remove 97995 Wave Disc.
  • Page 27 4. Use 96346 Bearing Separator (2") and 96232 Arbor Press (#2) to remove 02649 Bearing. Ÿ Use Ø 5/16" flat-end drive punch to push spindle from bearing.
  • Page 28 Hydraulic Press Bevel Gear 54917 Bearing 5. Support 54917 Bearing in a hydraulic press with spindle pointing down. Ÿ Push spindle from 54917 Bearing and bevel gear, removing both at the same time. Gear disassembly completed. Clean and inspect parts. Replace all parts that are worn or damaged.
  • Page 29 Gear Assembly: Press Tool 54917 Bearing 1. Use press to install 54917 Bearing onto spindle. Ÿ Press until fully seated on spindle.
  • Page 30 Bevel Gear PRESS UNTIL FULLY SEATED ON SPINDLE GEAR INSTALLATION COMPLETED 2. Use press to install bevel gear onto spindle. Ÿ Press until fully seated on spindle.
  • Page 31 96240 Bearing Press Tool 02649 Bearing PRESS UNTIL LEVEL WITH TOP OF SPINDLE • GAP 02649 INSTALLATION COMPLETED 3. Use press and 96240 Bearing Press Tool to install 02649 Bearing onto spindle. Ÿ Press until bearing is level with top of spindle.
  • Page 32 4. Fasten housing in vise (bronze or aluminum jaws). Install spindle assembly in housing. Ÿ By hand, push down on spindle assembly and rotate spindle back and forth to check the amount of free movement (“backlash”) between the bevel and pinion gear teeth.
  • Page 33 5. Install 97995 Wave Disc.
  • Page 34 96747 GEAR GREASE (14 grams) GREASE GREASE GREASE 6. Apply 14 grams of 96747 Grease to housing cavities and pinion gear. Ÿ Notice: Do not apply grease in “top spindle bearing pocket”. Assembly will be difficult! Ÿ Install shims and spindle assembly.
  • Page 35 Final Assembly: Lubrication: Ÿ Motor: Dynabrade recommends 1 drop of oil per minute for every 20 SCFM. Example: Specification states 115 SCFM, set lubricator for ~6 drops/per minute. Ÿ Gears: Replace grease at 1000 hours of use or when tool is rebuilt. Apply 14 grams of 96747 Grease according to instructions.
  • Page 36 Torque screws to: 9 N•m/~80 lbs. in. 8. Important: Use all five 96274 Screws to fasten guard (7" or 9") securely. • Torque screws to: 9 N•m/~80 lbs. in.

This manual is also suitable for:

Sander series