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Important: Manufacturer's warranty is void if tool is disassembled before warranty expires.
A motor tune-up kit is available (P/N 96047) is available to help maintain motor in peak operating condition.
Tool Disassembly:
1. Remove drill chuck and 53163 Side Handle.
2. Carefully secure the tool in a vise so that the spindle is pointing up. To avoid damaging the housing do not over tighten the vise.
3. Remove the 53185/55030/55029 Cover by turning it clockwise. (Left Hand Thread)
4. Pull the air motor from the housing.
5. Remove the 56028 Muffler Cap. To remove the 57066 Muffler Body use the 96034 12mm Hex Key.
Motor Disassembly:
1. Secure a 2 in. bearing separator around the end of the cylinder closest to the rear bearing plate. Place the separator on the table of the 96232 Arbor press so that the front
of the motor is pointing down.
2. Use a 5/32" dia. flat end drive punch as a press tool and push the rotor out of the 02649 Bearing.
3. Remove the 02649 Bearing from the rear bearing plate with the 96213 Bearing Removal Tool and the arbor press.
4. Front Bearing/Plate Removal:
A. To remove the front bearing/plate from the 04009 Rotor, use the 2 in. bearing separator and the arbor press by pushing the pinion end of the rotor out of
the 01007 Bearing.
B. To remove the front bearing/plate from the 55025 Rotor, secure the body of the rotor in a soft aluminum or bronze jaw vise and remove the 55038 Spindle Nut by
turning it counterclockwise. The 01007 Bearing and the 01010 Spacer are both a slip fit to the plate and the rotor.
Planetary Gear Disassembly:
1. To remove the planetary gear assemblies from the 53185/55030 Cover remove the 04014 Set Screw(s).
2. Push the planetary assembly(ies) out of the 53185/55030 Cover. (Use the arbor press if needed.)
3. Fasten a 2 in. bearing separator between the rear 02552 Bearing(s) and place the separator on the arbor press so that the planetary carrier spindle/pinion points down.
Use the larger end of the 96214 bearing Removal Tool to press the planetary carrier(s) out of the rear 02552 Bearing.
4. Remove the shafts and gears from the planetary carrier(s).
5. Use the bearing separator to also remove the front 02552 Bearing from the 53164 Planetary Carrier.
6. Carefully secure the 53165 Planetary Carrier in a soft aluminum or bronze jaw so that its' spindle is pointing up. Remove the 04114 Spindle Nut turning it counterclockwise.
7. Fasten a 2 in. bearing separator between the front 02552 Bearing and the 53165 planetary Carrier. Place these on the arbor press with the spindle pointing up and press
the planetary carrier from the bearing.
8. Remove the 55031 Felt Seal from the cover.
Valve Disassembly:
1. Drive 96025 Pin from housing and pull the valve stem assembly from the housing.
2. To remove the 55051 Valve Stop use a 3/32" dia. flat end drive punch as a press tool, and with the aid of a small separator and an arbor press, push the 55052.
3. Press 55052 Valve Stem through the second 55051 Valve Stop.
Valve Assembly:
1. Install 96069 Spring and slide 55039 Bushing (with o-rings) onto valve stem/trigger assembly.
2. Apply a small amount of #609 Loctite (or equivalent) onto 55052 Valve Stem and press the first 55051 Valve Stop with large end facing away from the 55039 Bushing.
3. Install 96147 O-Ring onto the second 55051 Valve Stop.
4. Apply a small amount of #609 Loctite (or equivalent) onto 55052 Valve Stem and press the second 55051 Valve Stop onto the valve stem with large end facing away from
the 55039 Bushing. Important: Press the second valve stop onto the valve stem only until the large end of the valve stop is flush with the end of the valve stem.
5. Install the valve assembly into the housing and secure it with the 96055 Pin.
Motor Assembly:
Important: Clean and inspect all parts before assembling.
1. Install 01010 Spacer on the rotor.
2. Install .003" thickness of shims into 53183/55026 Front Bearing Plate. Install 01007 Bearing into the front bearing plate.
3. Front Bearing/Plate Installation:
A. Use the 96244 Bearing Press Tool and arbor press to install the 53183 Front Bearing Plate along with 01007 Bearing onto the 04009 Rotor. (Place the tool against
the inner race of the bearing.)
B. Slip the 55026 Front Bearing Plate along with the 01007 Bearing onto the 55025 Rotor. Secure the body of the 55025 Rotor in a soft aluminum or bronze jaw vise and
install the 55038 Spindle Nut. (Torque to 17 N•m/150 in.-lbs.)
4. Use a .001" feeler gage to check clarence between the front of the rotor body and the face of the front bearing plate. That clarence must be .001"-.0015". If it is necessary
to adjust the clarence, do this by adding or removing the appropriate thickness in shims.
5. Apply Dynabrade Air Lube 95842 to the 01185 Blades and install these into the rotor slot.
6. Install the 01028 Cylinder so that the air inlet area lines up with the air inlet holes in the rear bearing plate.
7. Use the 96240 Bearing Press Tool and arbor press to install the 02649 Bearing into the 55027/01743 Rear Bearing Plate (press tool against the outer race of the bearing).
8. Use the 96240 Bearing Press Tool and arbor press to install the rear bearing/plate onto the 04009/55025 Rotor (press tool against the inner race of the bearing).
Important: The fit must be snug between the bearing plates and the cylinder. However, if its' too tight the rotor will turn freely. In that case the fit must be loosened
so that the rotor will turn freely while still maintaining a snug fit.
Planetary Gear Assembly:
1. Press the front 02552 Bearing onto the front of the 53164/53165 Planetary Carrier.
2. Install the 04114 Spindle Nut onto the 53165 Planetary Carrier. (Torque to 17 N•m/150 in.-lbs.)
3. Lubricate the planetary gears, needle bearings, and shafts with P/N 95542 Grease, and install these into the planetary carrier.
Disassembly/Assembly Instructions
(Models: 53390, 53391, 53060 and 53095)
(Models: 53390, 53391, 53060 and 53095)
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