Dynabrade 95809 User Manual
Parts Page Reorder No. PD96•29
Effective May, 1996
95809 Tune-Up Kit
For use with:
3,200 RPM Angle Head Tools
Parts included in kit are identified. See reverse side for Tune-up Instructions.
02649 Bearing
54514 Blades (5) (5/pkg.)
54515 Spacer
11016 Bearing
01017 Pin
01041 Grease Fitting
54523 O-Ring
54508 O-Ring
01022 Spring
01024 O-Ring
01025 O-Ring
54520 Bearing
54520 Bearing
54529 Shim Packet (as req.)
95398 Bearing
54545 Shim54542 Ball Bearing
54536 Shim
54542 Ball Bearing
01041 Grease Fitting
For Models succeeding serial number N24309
54537 Ball Bearing
95398 Ball Bearing
54529 Shim54531 Needle Bearing
54536 Shim
54534 Ball Bearing
01041 Grease Fitting
For Models prior to serial number N24309
54537 Ball Bearing
*54567 Spindle Puller
*54568 Spindle Wrench
*For use with models prior to S/N N24309 Only
®
DYNABRADE
Tune-Up Instructions
Important: Manufactures warranty is void if tool is disassembled before warranty expires.
Refer to the appropriate parts page for additional part identification.
Motor Disassembly:
1. Secure tool in a soft jaw vise holding onto wrench flats on rear of motor housing.
2. Secure lock ring with a wrench and twist angle housing from motor housing (Note: Left hand threads).
3. Remove 54526 Adapter from motor housing and loosen 01040 Lock Screw.
4. Pull planetary gear assembly from motor housing. Pull motor from housing (if motor does not pull out freely, lightly tap end of housing with a rubber mallet).
5. Clamp a bearing separator between the 54522 Ring Gear of the planetary carrier assembly and front 54520 Bearing (nearest to spindle end of assembly).
Press bearing from carrier.
6. Remove ring gear and gears. Press rear 54520 Bearing from planetary carrier.
7. Press rotor from 02649 Bearing and front bearing plate. Remove 54515 Spacer, cylinder and 54514 Blades from rotor. Press 11016 Bearing from rear bearing plate.
8. Remove 54505 Plug from motor housing. Remove valve assembly.
9. Remove 95713 Inlet Adapter. Pry retaining ring from rear of housing and remove 54524 Muffler and 54523 O-Ring.
Motor disassembly complete.
Motor Reassembly:
Important: Be sure parts are clean and in good repair before reassembly. Follow all torque, grease and lubrication instructions.
1. Insert a .002" shim from 54529 Shim pack into front bearing plate.
2. Insert new 02649 Bearing into front bearing plate.
3. Place new 54515 Spacer onto pinion end of rotor. Make sure countersink faces rotor.
4. Press from bearing plate assembly onto rotor until tight against spacer.
5. Check clearance between rotor and bearing plate. Apply an outward (pulling) pressure on rotor. If rotor rubs bearing plate, reduce the spacing by removing shim or substitute
with .001" shim.
6. Insert new 54514 Blades (lubricate blades with Dynabrade Air Lube P/N 95842 or equivalent before installation).
7. Place cylinder over rotor. Be sure pin holes and air inlet holes align with holes in bearing plate.
8. Press new 11016 Bearing into rear bearing plate and press assembly onto rotor. Be sure pin holes and air holes line up with holes in cylinder.
9. Insert motor assembly into housing. The pin in front bearing plate should enter guide slot in housing wall.
10. Install 54517 Spacer with unrelieved face towards front bearing plate.
11. Press new 54520 Bearing onto front end of planetary carrier.
12. Replace gears, gear shafts and ring gear (notches face rear of carrier).
13. Press new 54520 Bearing onto carrier (there should be a slight drag between ring gear and bearings).
14. Install planetary assembly onto motor housing. Line-up notches in ring gear with hole in housing for lock screw.
15. Install lock screw until snug, then back off 1/2 turn.
16. Install 54526 Adapter onto motor housing.
17. Install new O-rings and spring stem assembly and replace into motor housing.
18. Install new 54523 O-Ring onto muffler and replace into housing. Replace snap ring and inlet adapter.
Motor reassembly complete.
Angle Head Assemblies:
1. Remove retaining nut from angle housing with 5/8" hex key.
2. Slide spindle assembly from housing and disassemble.
3. Remove bearing cap with pin wrench and remove work spindle assembly.
4. Install new 54542 Bearing and 54537 Bearing onto work spindle and insert into housing.
5. Install bearing cap and test for end play. Spindle should turn freely. If there is excessive end play, insert new 54536 Shim behind 54542 Bearing.
6. Reassemble spindle assembly using new 54542 Bearing, 95398 Bearing and 54545 Shim Pack (as required). Replace and tighten retaining nut.
7. Test for backlash between gears. There should be .002" to .003" Backlash. Adjust using 54545 Shim Pack.
Note: 54567 Spindle Puller and 54568 Spindle Wrench (or equivalent) required. These tools are not included with tune-up kit.
1. Remove retaining nut from angle housing with 5/8" hex key.
2. Insert 54568 Spindle wrench into spline adapter of spindle and unscrew.
3. Screw female threaded end of 54567 Spindle Puller onto gear spindle. Tighten puller ring until gear spindle and 54531 Needle Bearing are removed from angle housing.
4. Remove bearing cap with pin wrench and remove work spindle assembly.
5. Install new 54534 Bearing and 54537 Bearing onto work spindle and insert into housing.
6. Install bearing cap and test for end play. Spindle should turn freely. If there is excessive end play, insert new 54536 Shim behind 54534 Bearing.
7. Insert gear spindle into housing, make sure teeth line up.
8. Install new 54531 Needle Bearing into housing and onto gear spindle. Using bored end of 54568 Spindle Wrench, press 54531 Needle Bearing over gear spindle down to gear.
9. Line up hole in housing with hole in gear spindle and lock together using a 3mm pin.
10. Install 95398 Bearing onto spline adapter and using 54568 Spline Wrench, tighten spline adapter onto gear spindle.
11. Replace and tighten retaining nut.
12. Test for backlash between gears. There should be .002" to .003" backlash. Adjust using 54529 Shim Pack.
Reattach angle housing to motor housing and secure with lock ring.
Motor should operate at 3,200 RPM at 90 PSI (6.2 Bar). RPM should be checked with a tachometer. If machine is running at a higher RPM then the tool should be serviced to
correct the cause before use. Before operating, Dynabrade recommends that 2-3 drops of pneumatic tool oil be placed directly into air inlet with throttle lever depressed and that
the gears be be greased through the grease fitting located on the motor and angle housings.
For models succeeding S/N N24309.
For models prior to S/N N24309.
See inside for Important Operating, Maintenance and Safety Instructions.
Parts Page Reorder No. PD94•31
Model:
50046 — Angle-Head Kit
54002 — Mini-Dynorbital Sander
54003 — Mini-Dynorbital Sander
50223 — 2" Disc Sander
51091 — Die Grinder
53026 — Drill
50047 — 3" Buffer
50070 — Finesse Sanding Kit
Effective April, 1994
Always operate, inspect and maintain this tool in accordance with the Safety Code for portable air tools
(ANSI B186.1) and any other applicable safety codes and regulations. Please refer to Dynabrade's
Warning/Safety Operating Instructions for more complete safety information.
Machine and Motor Parts
For Serial Number N24309 and Higher
3,200 RPM Angle-Head
54512 Cylinder
01041 Grease Fitting
02649 Bearing
54529 Shim Packet (as req.)
54514 Blades (5) (5/pkg.)
54516 Bearing Plate
(Incl. 01009 Pin and 01042 Pin)
54511 Bearing Plate
(Incl. 01009 Pin)
11016 Bearing
01040 Lock Screw
01009 Pin
01009 Pin
01042 Pin
54515 Spacer
54513 Rotor (Incl. 54515 Spacer)
54519 Gear (2)
(Incl. 01033 Needle Bearings)
54509 Housing
(Incl. 54510 Valve Bushing, 01041 Grease Fitting)
01016 Lever 54524 Muffler
95713 Adapter
54508 “O” Ring
01022 Spring
01024 “O” Ring
54506 Regulator
(Incl. 01024 “O” Ring)
01025 “O” Ring
54526 Adapter
(right hand threads)
(left hand threads)
54527 Lock Ring
(left hand threads)
54540 Retaining Nut
(left hand threads)
01053 Bearing
54541 Spindle
54542 Ball Bearing
54545 Shim Pack (as req.)
54546 Bevel Gear
54547 Housing
54536 Shim Pack (as req.)
54542 Ball Bearing
54537 Ball Bearing
54550 Bearing Cap (left hand threads)
54549 Work Spindle
54505 Plug
(Incl. 01025 “O” Ring)
54507 Valve Stem
(Incl. 54508 “O” Ring)
54523 “O” Ring
54525 Retaining Ring
01017 Pin
54517 Spacer
54520 Bearing
54518 Shaft (2)
01033 Needle Bearing (2)
54521 Carrier
54522 Ring Gear
54520 Bearing
!
WARNING
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