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Dynabrade 4657971919 Disassembly & Assembly Instructions

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Important: Use these instructions along with the tool parts page or manual.
Notice: To avoid damage, use the special repair tools contained in the 57098 Motor Repair Kit.
Shut off the air supply and deplete air from the hose. Disconnect the tool from the air supply.
Motor Disassembly:
1. Position the 57092 Repair Collar around the housing.
Fasten the sander in a vise with the sanding pad facing up. Notice: Do not over tighten
the sander in the vise. Over tightening will make it difficult to remove the 57059 Lock
Ring. (SEE STEP #3)
Use a 3 mm hex key to remove the pad screws (4).
Disassembly Instructions – Dynabug Sander
3 mm hex key
57092 Repair Collar

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Summary of Contents for Dynabrade 4657971919

  • Page 1 Disassembly Instructions – Dynabug Sander Important: Use these instructions along with the tool parts page or manual. Notice: To avoid damage, use the special repair tools contained in the 57098 Motor Repair Kit. Shut off the air supply and deplete air from the hose. Disconnect the tool from the air supply. Motor Disassembly: 3 mm hex key 57092 Repair Collar...
  • Page 2 3/16" hex key Use a 3/16" hex key to remove the 96168 Screw. Use a Phillips screwdriver to remove the 96114 Screws (6). Remove the 57825 Pad Top.
  • Page 3 2. Use a slot-blade screwdriver to loosen the 96116 Clamp. Remove the clamp, 57822 Boot and 57823 Pad Mount. 3. Use the 56058 Lock Ring Wrench to loosen the 57059 Lock Ring. Turn counterclockwise.
  • Page 4 4. Pry-up, under the motor shaft balancer to remove the air motor from the housing.
  • Page 5 Remove the 57054 Rear Ring from the inside of the housing. 5. Use retaining ring pliers to remove the 95626 Retaining Ring.
  • Page 6 96346 Bearing Separator 6. Fasten the 96346 Bearing Separator (2") around the 57058 Cylinder. Place the bearing separator and motor in the 96232 Arbor Press (#2) with the counterweight pointing down. Use the arbor press and a 5/16" or 8 mm diameter flat-end press tool to push the shaft out of the 01206 Bearing.
  • Page 7 96214 Bearing Removal Tool 8. By hand, or with the arbor press, use the 96214 Bearing Removal Tool to remove the 01206 Bearing from the 57056 Rear Bearing Plate. 9. Balancer Bearing and Shaft Disassembly: a) Fasten the counterweight in a vise with aluminum or bronze jaws so that the hex of the 57069 Balancer Shaft is pointing up.
  • Page 9 b) To break the adhesive bond, use two flat-blade screwdrivers (large) to pry-up on the balancer shaft and bearing. Notice: If necessary, use a HEAT GUN to apply heat to the counterweight. Use the 56056 Bearing Puller to remove the balancer shaft and the 56052 Bearing.
  • Page 10 c) Fasten the bearing separator between the 56052 Bearing and the hex end of the 57069 Balancer Shaft. Place the bearing separator and the balancer shaft in the arbor press with the hex end pointing down. Use the arbor press ram to break the adhesive bond. Use a 5/16"...
  • Page 11 Clean and inspect all parts before assembling. Assembly Instructions – Dynabug Sander Motor Assembly: 1. Balancer Bearing and Shaft Assembly:...
  • Page 12 a) Install the 95630 Snap Ring around the 59084 V-Seal. Loctite #271 b) Install the 59084 V-Seal along with the 95630 Snap Ring onto the 57069 Balancer Shaft. Place the flexible lip of the seal toward the hex end of the balancer shaft so that the flat side is toward the 56052 Bearing.
  • Page 13 57091 Bearing Press Tool d) Use the small diameter end of the 57091 Bearing Press Tool, and the 96232 Arbor Press (#2) to install the 56052 Bearing (seal side toward hex). Press the bearing all the way onto the balancer shaft until the bearing is tight against the step on the shaft.
  • Page 14 Loctite #271 2. Apply a small amount of Loctite #271 or equivalent to the outside diameter of the 56052 Bearing. Install the balancer shaft with bearing into the bore of the motor shaft balancer.
  • Page 15 3. Compress the 95630 Snap Ring into the groove in the motor shaft balancer.
  • Page 16 4. Use the large diameter end of the 57091 Bearing Press Tool and the arbor press to install the 57088 Bearing onto the motor shaft balancer.
  • Page 17 57055 Front Ring 95975 Washer 57059 Lock Ring IMPORTANT: For all models install the 57059 Lock Ring, 95973 Washer and 57055 Front Ring onto the motor shaft balancer at this point.
  • Page 18 5. Use the large diameter end of the 57091 Bearing Press Tool, and the arbor press to install the 57057 Front Bearing Plate. 56047 Key 6. Install the 56047 Key and rotor onto the motor shaft balancer. The rotor should slide up and down easily on the motor shaft.
  • Page 19 7. Apply the 95842 Dynabrade Air Lube 10W/NR or equivalent to the vanes and install them into the rotor. 96244 Bearing Press Tool 8. If necessary, use the RAISED OUTSIDE DIAMETER of the 96244 Bearing Press Tool and the arbor press to install the 01206 Bearing into the 57056 Rear Bearing Plate.
  • Page 20 9. Install the 57058 Cylinder so that the short line-up pin fits into the front bearing plate. Use the arbor press ram to align and start the 01206 Bearing and rear bearing plate onto the motor shaft. JUST TOUCH 10. Use the small diameter end of the 57091 Bearing Press Tool and the arbor press to install the bearing/plate onto the motor shaft balancer.
  • Page 21 11. Use retaining ring pliers to install the 95626 Retaining Ring. Push the arch of the retaining ring into the groove.
  • Page 22 12. Install the 57054 Rear Ring.
  • Page 23 APPLY AIR MOTOR 13. Apply air motor oil to the rubber rings.
  • Page 24 14. Sight the cylinder line-up pin with the notch on the inside of the housing. Also, sight the line- up guide on the housing and install the motor.
  • Page 25 1) CLICK 2) FASTEN 56058 Lock Ring Wrench 15. By hand, use the 56058 Lock Ring Wrench to locate thread and fasten motor in housing. Turn 56058 counterclockwise until you hear CLICK. Turn 56058 clockwise to fasten motor in housing.
  • Page 26 T to 28 N•m/~250 in. lbs. 16. Position the 57092 Repair Collar around the housing. Fasten the sander in a vise with the counterweight pointing up. Notice: Do not over tighten the sander in the vise or it will be difficult to install the 57059 Lock Ring.
  • Page 27 FRONT (T to 1.6 N•m/~14 in. Lbs.) 57823 PAD MOUNT 57837 WASHER AIR-BLEED BACK 17. Install the 57823 Pad Mount into the 57822 Boot and position the boot onto the 57825 Pad Top with the air-bleed hole facing back. Fasten the pad mount and boot to the pad top with the 96114 Screws (6).
  • Page 28 18. Align the balancer shaft with matching hex socket and install.
  • Page 29 T to 0.7 N•m/~6 in. lbs. PATH OF 1/16" (~1.6 MM) VACUUM OPENING 19. Install 96116 Clamp over the housing and around the 57822 Boot. Position the top edge of the clamp even with the top of the boot. The clamp tightening screw must clear the path of the vacuum opening, and the abrasive clip mechanism.
  • Page 30 Valve, Exhaust and Vacuum Assembly: For the parts list and the order of assembly, refer to the exploded view found in the parts page or tool manual. Shop for quality Dynabrade products on our website. Discover other air sanders and polishers on our website.