Valve Disassembly - Dynabrade Dynabug II Safety, Operation And Maintenance Manual

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Disassembly/Assembly Instructions – Dynabug
Important: Manufacturers warranty is void if the tool is disassembled before the warranty expires.
The Tool Repair Kit 57874 is available. This kit includes:
(12mm) Hex Key and (3/4") 96066 Socket. These will assist in the disassembly and assembly of the Dynabug
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
3. Use a Phillips Screwdriver to remove the (4) screws, (4)
4. Insert a 3/16" dia. drive punch through one of the holes in the pad base to prevent the shaft balancer from rotating. Use the 95266, (3mm) Hex Key to remove the
95344 Screw along with the 95935
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
8. Use the 56058 Lock Ring Tool to loosen the
9. Remove the 57896 Felt Seal from the shaft balancer and pull the motor out of the housing. Remove the
10. Use retaining ring pliers to remove the
11. Fasten the 96236 (2") Bearing Separator around the part of the
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
13. Remove the rotor, blades, and key.
14. Use the arbor press to push the shaft balancer, the
15. Remove the lock ring and the 59057
16. Use the bearing separator and the arbor press to remove the
Motor Disassembly Complete.

Valve Disassembly:

1. Use a 2.5mm drive pin punch to remove the
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
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 shaft balancer so that the side marked 'OFF' is toward the counterweight.
2. Install the 59083 Felt Washer into the
3. Use the small end of the 57091 Bearing Press Tool along with the arbor press to install the
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
Note: Pull the 59057 Seal up tight against the
5. Install the 56047 Key and the 57113
(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
8. Align the cylinder line-up pin with the hole in the rear bearing plate. Use the small end of 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 convex side up 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
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
arbor press so that the bearing pocket is facing up. Use the flat face of the arbor ram to push the
surface of the pad base.
18. Use the arbor press and the small end of the
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
equivalent) to the internal threads of the shaft balancer and install the
20. Use a Phillips Screwdriver to install the (4)
pad toward the back of the sander so that it will align with the vacuum tube.
Motor Assembly Complete.
Buy parts on line at https://Dynashop.co.uk/ for all things Dynabrade
56058 Lock Ring Tool,
56046 Lock Ring and the motor difficult.
96538 Washers and sanding pad.
Washer by turning it counterclockwise.
96232 (#2) Arbor Press to remove the
56046 Lock Ring by turning it counterclockwise.
98463 Retaining Ring.
59051 Cylinder that is closest to the
58368 Bearing can be removed from the bearing plate with the
59083 Felt Washer, and the
Seal.
58368 Bearing and the felt washer from the shaft balancer.
94590 Pin, 57888 Throttle Lever and
95697 Retaining Ring and push the
59057 Seal and place these onto the shaft balancer. (See Drawing 1)
57893 Front Bearing Plate onto the
57893 Front Bearing Plate.
Rotor/blades (5) onto the shaft balancer. Note: These should be lubricated with the
57891 Rear Bearing Plate.
56046 Lock Ring by turning it clockwise. Torque to 17 N·m/150 lbs. in. Note: Apply a slight amount of pressure down onto
® #271 (or equivalent) in two places on the inside of the pad base bearing pocket. Place the pad base on the tool plate of the
57091 Bearing Press Tool to carefully install the pad base with the bearing onto the shaft balancer. Align the (4)
95344
96539 Screws, (4) 96538 Washers and sanding pad. Note: When installing a vacuum pad orient the open oval pocket in the
57092 Repair Collar, 57091 Bearing Press Tool,
IIOrbital Sander. Please refer to the parts breakdown
®
54552 Bearing from the pad base.
01024 O-Ring from the cylinder.
57891 Rear Bearing Plate.
58368 Bearing out of the 57893 Front Bearing Plate.
57041 Comfort Platform.
59075 Speed Regulator out of the housing.
58368 Bearing onto the shaft balancer. (See Drawing 2)
58368 Bearing. (See Drawing 3)
57091 Bearing Press Tool along with the arbor press to install the
54552 Bearing into the pad base until the bearing is flush with the
Screw along with the 95935 Washer. Torque to 5 N·m/45 lbs. in.
5
® II Sander
95266 (3mm) Hex Key, 96034
96214 Bearing Removal Tool and the arbor press.
95842 Dynabrade Air Lube
® #243 (or
57890