Dynorbital-Spirit 59000 Leitfaden

SAFETY INSTRUCTIONS

Carefully Read all instructions before operating or servicing any Dynabrade®Abrasive Power Tool.

Products offered by Dynabrade are not to be modified, converted or otherwise alerted from the original design without expressed written consent from Dynabrade, Inc.

Tool Intent: Dynorbital-Spirit™ Random Orbital Sander is used for sanding and finishing a variety of materials including wood, metal, plastic, fiberglass, solid surfaces,

composites, rubber, glass and stone. Do Not Use Tool For Anything Other Than Its IntendedApplications.

Training: Proper care, maintenance, and storage of your tool will maximize its performance.

• Employer's Responsibility – Provide Dynorbital-Spirit™ operators with safety instructions and training for safe use of tools and accessories.

Accessory Selection:

• Abrasive/accessory RPM (speed) rating MUST be approved for ATLEAST the tool RPM rating.

• Before mounting an accessory, visually inspect for defects. Do not use defective accessories.

• Follow tool specifications before choosing size and type of accessory.

• Only use recommended fittings and air line sizes. Air supply hoses and air hose assemblies must have a minimum working pressure rating of 150 PSIG (10 bars, g) or 150

percent of the maximum pressure produced in the system, whichever is higher. (See Tool Machine Specifications Table.)

• DO NOT use – ...................................................... OPERATING INSTRUCTIONS

Warning: Always wear eye protection. Operator of tool is responsible for following: accepted eye, face, respiratory, hearing and body protection.

Caution: Hand, wrist and arm injury may result from repetitive work, motion and overexposure to vibration.

(continued on next page)

Parts Page Reorder No. PD03•07

Effective January, 2003

Supersedes PD02•59

Dynorbital-Spirit™

Air Tool Manual – Safety, Operation and Maintenance

Models:

3/8" Orbit 3/16" Orbit 3/32" Orbit

59000 59010 59015 59025 59030 59040

59001 59011 59016 59026 59031 59041

59002 59012 59017 59027 59032 59042

59003 59013 59018 59028 59033 59043

59004 59014 59019 59029 59034 59044

59005 59100 59020 59105 59035 59110

59006 59101 59021 59106 59036 59111

59007 59102 59022 59107 59037 59112

59008 59103 59023 59108 59038 59113

59009 59104 59024 59109 59039 59114

FOR COMPLETE MODEL DESCRIPTION REFERENCE PAGE 6.

SAFETY LEGEND

WARNIN

WARNING

Read and understand tool manual before

work starts to reduce risk of injury to

operator, visitors, and tool.

WARNING

Eye protection must be worn at all times,

eye protection to conform to ANSI Z87.1.

WARNING

Respiratory protection to be used when exposed to

contaminants that exceed the applicable threshold

limit values required by law.

WARNING

Practice safety requirements. Work alert,

have proper attire, and do not operate tools under

the influence of alcohol or drugs.

WARNING

Ear protection to be worn when exposure to sound,

exceeds the limits of applicable Federal, State or

local statues, ordinances and/or regulations.

WARNING

Air line hazard, pressurized supply lines and flexible

hoses can cause serious injury. Do not use dam-

aged, frayed or deteriorated air hoses and fittings.

Read and understand this tool manual before operating your air tool. Follow all safety rules for the protection of operating person-

nel as well as adjacent areas. Always operate, inspect and maintain this tool in accordance with the American National Safety

Institute (ANSI) Safety Code for Portable Air Tools – B186.1. For additional safety information, refer to Safety Requirements for the

Use, Care and Protection of Abrasive Wheels – ANSI B7.1, Code of Federal Regulation – CFR 29 Part 1910, European Committee for

Standards (EN) Hand Held Non-Electric Power Tools – Safety Requirements and applicable State and Local Regulations.

SAVE THIS DOCUMENT, EDUCATE ALL PERSONNEL

12,000 RPM Air Powered Random Orbital Sander

For Serial No. 3B1000B and Higher

To Tool Station

Closed Loop Pipe System

(Sloped in the direction of air flow)

Ball

Valve

Ball

Valve

Filter

Coupler

Regulator

Lubricator

Air Flow

Drain

Valve

Drain

Valve

Air Tool Air Compressor

and Receiver

Drain Valve

Air Hose

90 PSIG MAX

(6.2 Bar)

Air Flow

Refrigerated

Air Dryer

Filter

Regulator

Lubricator

90 PSIG

(6.2 Bar)

OPERATING INSTRUCTIONS (continued)

• Keep hand and clothing away from working end of the air tool.

Operation: Be sure that any loose clothing, hair and all jewelry is properly restrained.

• Secure inlet bushing on air tool with a wrench before attempting to install the air fitting to avoid damaging housing assembly.

• Check tool RPM (speed) with tachometer with air pressure set at 90 PSIG while the tool is running. If tool is operating at a higher speed than the RPM marked on the tool

housing, or operating improperly, the tool must be serviced and corrected before use.

Caution: Tool RPM must never exceed abrasive/accessory RPM rating. Check accessory manufacturer for details on maximum operating speed or special

mounting instructions.

• With power source disconnected from air tool, mount recommended accessory into collet assembly.

• Connect air tool to power source. Be careful NOT to depress throttle lever in the process. Do not expose air tool to inlet pressure above 90 PSIG or (6.2 Bars).

Caution: After installing the accessory, before testing or use and/or after assembling tool, the Dynorbital-Spirit™ must be started at a reduced speed to check for good

balance. Gradually increase tool speed. DO NOT USE if tool vibration is excessive. Correct cause, and retest to insure safe operation.

• Make sure that work area is uncluttered, and visitors are at a safe range from the tools and debris.

• Use a vise or clamping device to hold work piece firmly in place.

• Do not apply excessive force on tool or apply “rough” treatment to it.

• Always work with a firm footing, posture and proper lighting.

Report to your supervisor any condition of the tool, accessories, or operation you consider unsafe.

Air System

1DROP/MIN.

20 SCFM

LUBRICATOR SETTING

•Ideally the air supply should be free from moisture.

Incorporating a refrigerated air dryer after the

compressor and drain valves at each tool station

(as shown) further reduces moisture from

condensation in the air supply.

•DynabradeAir Power Tools are designed to

operate at 90 PSIG (6.2 Bar/620 kPa) maximum

air pressure at the tool inlet, when the tool is

running. Use recommended regulator to control

air pressure.

➤➤

➤

Maintenance Instructions

Important: APreventative Maintenance Program is recommended whenever portable power tools are used.

•Use only genuine Dynabrade replacement parts to insure quality. To order replacement parts, specify Model#, Serial# and RPM of your air tool.

•All Dynabrade Rotary Vane air tools must be used with a Filter-Regulator-Lubricator to maintain all warranties. Dynabrade recommends the following:

11405 Air Filter-Regulator-Lubricator (FRL) – Provides accurate air pressure regulation and two stage filtration of water contaminants. Operates 40

SCFM/1,133 LPM @ 100 PSIG with 3/8" NPT female ports.

•Dynabrade recommends one drop of air lube per minute for each 20 SCFM (example: if the tool specification states 40 SCFM, set the drip rate on the

filter-lubricator to 2 drops per minute). DynabradeAir Lube (P/N 95842: 1 pt 473 ml) is recommended.

Routine Preventative Maintenance: Check free speed of Dynorbital-Spirit™ using a tachometer.

•Mineral spirits are recommended when cleaning the tool and parts. Do not clean tool or parts with any solvents or oils containing acids, esters,

ketones, chlorinated hydrocarbons or nitro carbons.

•DO NOT clean or maintain tools with chemicals that have a low flash point (example: WD-40®).

•ADrop-In Motor and Tune-Up Kit are available, see specific kit number on page 9.

•Air tool stampings must be kept legible at all times, if not, reorder and replace. User is responsible for maintaining specification information i.e.:

Model #, S/N, and RPM.

•Blow air supply hose out prior to initial use.

•Visually inspect air hoses and fittings for frays, visible damage and signs of deterioration. Replace damaged or worn components.

•Refer to Dynabrade's Warning/Safety Operating Instructions Tag (Reorder No. 95903) for safety information.

After maintenance is performed on tool, add a few drops of DynabradeAir Lube (P/N 95842) to the air line and start the tool a few times to lubricate air motor.

Check for excessive tool vibration.

Handling and Storage:

•Protect tool inlet from debris (See Notice Below).

•DO NOT carry tool by air hose.

•Protect abrasive accessories from exposure to water, solvents, high humidity, freezing temperature and extreme temperature changes.

•Store accessories in protective racks or compartments to prevent damage.

Notice

All Dynabrade motors use the highest quality parts and materials available and are machined to exacting tolerances. The failure of quality pneumatic motors

can most often be traced to an unclean air supply or the lack of lubrication. Air pressure easily forces dirt or water contained in the air supply into motor

bearings causing early failure. It often scores the cylinder walls and the rotor blades resulting in limited efficiency and power. Our warranty obligation is

contingent upon proper use of our tools and cannot apply to equipment which has been subjected to misuse such as unclean air, wet air or a lack of

lubrication during the use of this tool.

One Year Warranty

Following the reasonable assumption that any inherent defect which might

prevail in a product will become apparent to the user within one year from

the date of purchase, all equipment of our manufacture is warranted

against defects in workmanship and materials under normal use and

service. We shall repair or replace at our factory, any equipment or part

thereof which shall, within one year after delivery to the original purchaser,

indicate upon our examination to have been defective. Our obligation is

contingent upon proper use of Dynabrade tools in accordance with factory

recommendations, instructions and safety practices. It shall not apply to

equipment which has been subject to misuse, negligence, accident or

tampering in any way so as to affect its normal performance. Normally

wearable parts such as bearings, contact wheels, rotor blades, etc., are not

covered under this warranty.

1. American National Safety Institute – ANSI

25 West 43rd Street

Forth Floor

New York, NY 10036

Tel: 1 (212) 642-4900

Fax: 1 (212) 398-0023

3. European Committee for Standardization

Rue de Stassart 36

B - 1050 Brussels, Belgium

2. Government Printing Office – GPO

Superintendent of Documents

Attn. New Orders

P.O. Box 371954

Pittsburgh, PA15250-7954

Tel: 1 (202) 512-1803

Reference Contact Information

Dynorbital-Spirit™

Complete Assembly

23 N•m T

Note: To order replacement parts specify the Model # and Serial # of your machine.

31 32

Oil: O1= Air Lube

Adhesive: A2= Loctite #271

A8= Loctite #567

Torque: N•m x 8.85 = In. - lbs.

KEY

23 N•m

See page 5 for Machine

Exhaust Assemblies.

Highly Recommended

Drop-in Complete Motor Assemblies

Orbit 3" & 3-1/2" 5" 6"

3/8" 59450 59453 59456

3/16" 59451 59454 59457

3/32" 59452 59455 59458

Orbit 3" & 3-1/2" 5" 6"

3/8" 59070 59071 59072

3/16" 59060 59061 59062

3/32" 59065 59066 59067

All above parts are included in Drop-in Motors.

Note: 59058 Lock Ring only included with

3/8" Orbit Drop-in Motors.

For assembly instructions, see page 6.

For Models:

59000, 59001, 59002, 59003, 59004, 59005, 59006

59007, 59008, 59009, 59010, 59011, 59012, 59013

59014, 59015, 59016, 59017, 59018, 59019, 59020

59059, 59022, 59023, 59024, 59025, 59026, 59027

59028, 59029, 59030, 59031, 59032, 59033, 59034

59035, 59036, 59037, 59038, 59039, 59040, 59041

59042, 59043, 59044, 59100, 59101, 59102, 59103

59104, 59105, 59106, 59107, 59108, 59109, 59110

59111, 59112, 59113, 59114

1Sanding Pads (See Pg. 10)

2Vacuum Lip-Seal Shroud

57089 5" & 6"

3Vacuum Shroud

57084 3 1/2"

4Shroud (Non-Vac)

54458 3-1/2"

56051 5" & 6" (Lip Seal)

595630 Snap Ring

657069 Balancer Shaft

759084 V-Seal

856052 Bearing

9Motor Shaft Balancer

10 56047 Key

98461 Key

11 59058 Lock Ring

12 50659 O-Ring

13 59057 “Top Hat” Seal

14 59083 Felt

15 58368 Bearing (2)

16 59076 Front Bearing Plate

17 57113 Rotor/Blade Set

18 01024 O-Ring

19 59051 Cylinder

20 59077 Rear Bearing Plate

21 98463 Retaining Ring

22 95697 Retaining Ring

23 Housing (See Chart, Pg. 6)

24 59054 Throttle Lever - 3/8"

59052 Throttle Lever - 3/16"

59053 Throttle Lever - 3/32"

25 98927 Pin

26 98459 O-Ring

27 58363 Valve Stem

28 58364 Speed Regulator

29 01025 O-Ring (2)

30 01464 Seal

31 58365 Tip Valve

32 01468 Spring

33 01494 Inlet Bushing

Index Key

No. Part # Description

Machine Exhaust Assemblies

Self Generated Vacuum (Vac-Ready)/Machine Exhaust

Central Vacuum/Machine Exhaust Non-Vacuum/Machine Exhaust

Vacuum Conversion Instructions..

To Disassemble:

1. Disconnect tool from power source. Invert machine and secure in vise, using 57092 Collar (supplied in 57098 Repair Kit) or padded jaws.

2. Remove sanding pad with 50679 (26 mm) Open-End Wrench (supplied with sander) and lip-seal shroud from housing.

3. Remove 56028 Muffler Cap and 56027 Muffler Insert (2) from 57066 Muffler Body. Using a 12 mm hex wrench (supplied in 57098 Repair Kit), remove

muffler body from housing (not applicable for Self-Generated Vac to Central Vac).

Non-Vac to Self-Generated Vac for Hook-Up to Self-Contained Dust Collection System

1. Attach 57083 VacuumAdapter to either 57084, 57086, 57087 Vacuum Overskirts or 57089 Vacuum Lip-Seal Shroud. Then attach to the housing making

sure the protrusions on the overskirt or shroud are aligned with the notches on the housing.

2. Place 95526 O-Ring on the muffler body between the shoulder and the four (4) protrusions. Using a 12 mm hex wrench, attach the muffler body and

o-ring to the housing through the vacuum adapter.

3. Place vacuum nozzle into the vacuum adapter with the slots facing outward making sure that the knob on the nozzle is aligned with the slot in the adapter.

4. Place 57067 Vacuum Tube into the vacuum adapter with the grooves facing inward until the adapter “snaps” onto the tube and the tube cannot be pulled

out. If the tube can be pulled out, rotate it 1/4 turn and place it back into the adapter until it “snaps”.

5. Rotate tube until holes line up. Insert dowel pin in holes until it is centered. Attach sanding pad, attach machine to portable dust collection system.

Non-Vac to Central Vac

1. Attach 57093 VacuumAdapter to either 57084, 57086, 57087 Vacuum Overskirts or 57089 Vacuum Lip-Seal Shroud. Then attach to the housing making

sure the protrusions on the overskirt or shroud are aligned with the notches on the housing.

2. Using a 12 mm hex wrench, attach the muffler body to the housing through the central vacuum adapter.

3. Place muffler cap with inserts on muffler body making sure that the protrusions on the body fit in the pockets on the cap.

4. Attach weight-mated vacuum sanding pad with 50679 (26 mm) Open-End Wrench. Attach machine to central vacuum system.

Self-Generated Vac to Central Vac

1. Remove 96197 Dowel Pin with an 1/8" drive pin. Remove 57067 Vacuum Tube from 57083 Vacuum Adapter by turning it clockwise while pulling backward.

2. Using a small flat screwdriver, pry vacuum nozzle until it is loose and then remove it by using two fingers to push and pull it until it hits the “legs” on

vacuum adapter. Place vacuum tube back into vacuum adapter far enough to push the “legs” back then push vacuum nozzle and vacuum tube

out the rest of way.

3. Using a 12 mm hex wrench (supplied in 57098 Repair Kit), remove the 57066 Muffler Body and 95526 O-Ring from the housing through the adapter.

Remove the o-ring from the muffler body.

4. Remove 57083 VacuumAdapter and attach 57093 Vacuum Adapter to either 57084, 57086, 57087 Vacuum Overskirts or 57089 Vacuum Lip-Seal Shroud.

Then attach to the housing making sure that the protrusions on the overskirt or shroud are aligned with the notches on the housing.

5. Using a 12 mm hex wrench, attach the muffler body and o-ring to the housing through the central vacuum adapter.

6. Place muffler cap with inserts on muffler body making sure that the protrusions on the body fit in the pockets on the cap. Attach sanding pad.

Central Vac to Self Generated Vac

1. Remove 57093 Central VacuumAdapter and put the 57083 Vacuum Adapter in its place.

(continued on next page)

Index Key

No. Part # Description

157083 VacuumAdapter

296197 Dowel Pin

357066 Muffler Body

495526 O-Ring

559088 Vac Nozzle

657067 Vac Tube

757093 VacuumAdapter

856027 Muffler Insert (2)

956028 Muffler Cap

10 59273 MufflerAssembly

123

3 8 9

456

Non-Vacuum to Vacuum Conversion Kits

Original Converts Kit

Non-Vac Tool to Part Number

3-1/2" (89 mm) Self-Generated Vac-Ready 57118

3-1/2" (89 mm) Central Vac-Ready 57119

5" (127 mm) Self-Generated Vac-Ready 57120

5" (127 mm) Central Vac-Ready 57121

6" (152 mm) Self-Generated Vac-Ready 57122

6" (152 mm) Central Vac-Ready 57123 Optional: 30 quantity Muffler Insert available, P/N 56054.

Vacuum Conversion Instructions (continued)

2. Place 95526 O-Ring on the muffler body between the shoulder and the four (4) protrusions. Using a 12 mm hex wrench (supplied in 57098 Repair Kit),

attach the muffler body and o-ring to the housing through the vacuum adapter.

3. Place vacuum nozzle into the vacuum adapter with the slots facing outward making sure that the knob on the nozzle is aligned with the slot in the adapter.

4. Place 57067 Vacuum Tube into the vacuum adapter with the grooves facing inward until the adapter “snaps” onto the tube and the tube cannot be pulled

out. If the tube can be pulled out, rotate it 1/4 turn and place it back into the adapter until it “snaps”.

5. Rotate tube until holes line up. Insert 96197 Dowel Pin in holes until it is centered. Attach machine to portable dust collection system.

Drop-in Motor Removal/Replacement Instructions - Dynorbital-Spirit™

Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires.

Drop-in Motor Repair Kit P/N 59459 is available which includes special repair tools for the correct removal and replacement of the air motor.

Disconnect tool from power source before motor exchange.

To Remove:

1. Disconnect the sander from the air supply.

2. Invert the sander, and place the 57092 Repair Collar (supplied in the 59459 Drop-in Motor Repair Kit) around the housing and secure in a vise. Padding

can be used on the vise jaws to protect the housing. Important: Do not over tighten the sander in the vise. If the sander is held too tight the removal

of the lock ring and air motor will be difficult.

3. Remove the sanding pad with the 50679 26 mm Open-end Wrench. (Supplied with the sander.)

4. Insert the 56058 Lock Ring Tool (supplied in the 59459 Drop-in Motor Repair Kit) into the corresponding tabs of the lock ring. Loosen the 59058 Lock

Ring turning it counterclockwise.

5. Remove the 59058 Lock Ring and the 50659 O-Ring from the air motor assembly. (3/32" and 3/16" dia. orbits only.)

6. Discard the air motor assembly.

To Install Replacement:

Important: Clean and inspect the housing, valve mechanism, and exhaust assembly. Replace any valve, muffler, or vacuum components as is necessary.

Follow all torque and lubrication specifications.

1. Place the 50659 O-Ring into the 59058 Lock Ring and slip these over the motor shaft balancer. (3/32" and 3/16" dia. orbits only.) Spread 1 drop of

pneumatic tool oil on the surface between the 50659 O-Ring and the 59076 Front Bearing Plate.

2. Apply 1 drop of oil to the 01024 O-Ring. (O-Ring is supplied with the drop-in air motor assembly.)

3. With the sander housing secured in a vise (use the 57092 Repair Collar of padding on the jaws of the vise to protect the housing) slide the drop-in air

motor into the housing aligning the line-up post with the notch on the inside of the housing. Note: Make certain that the line-up post enters the notch

in the housing and that the 01024 O-Ring remains seated in the side of the cylinder.

4. Tighten the lock ring with the 56058 Lock Ring Wrench. (Torque to 23 N•m/200 in.-lbs.)

5. Install a Dynabrade weight-mated sanding pad.

Drop-in Motor Replacement Complete.

Important: Before connecting the sander to the air supply. depress the throttle lever and place 2-3 drops of DynabradeAir Lube (P/N 95842) directly into the

sanders air inlet. The sander should now be tested at 90 PSIG operating pressure at the sanders air inlet. Operate the sander for 30 seconds to determine

if it is operating properly and to allow the lubricating oil to permeate the air motor.

Complete Model Description/Housing Number

Model Vacuum Housing

Number Description Number

59000 3-1/2" Non-Vacuum 56620

59001 3-1/2" Basic Vacuum 56621

59002 3-1/2" Deluxe Vacuum 56621

59003 3-1/2" Self Generated Vacuum 56621

59004 3-1/2" Central Vacuum 56622

59005 5" Non-Vacuum 56623

59006 5" Basic Vacuum 56624

59007 5" Deluxe Vacuum 56624

59008 5" Self Generated Vacuum 56624

59009 5" Central Vacuum 56625

59010 6" Non-Vacuum 56626

59011 6" Basic Vacuum 56627

59012 6" Deluxe Vacuum 56627

59013 6" Self Generated Vacuum 56627

59014 6" Central Vacuum 56628

59015 3-1/2" Non-Vacuum 56629

59016 3-1/2" Basic Vacuum 56630

59017 3-1/2" Deluxe Vacuum 56630

59018 3-1/2" Self Generated Vacuum 56630

59019 3-1/2" Central Vacuum 56631

Model Vacuum Housing

Number Description Number

59020 5" Non-Vacuum 56632

59021 5" Basic Vacuum 56633

59022 5" Deluxe Vacuum 56633

59023 5" Self Generated Vacuum 56633

59024 5" Central Vacuum 56634

59025 6" Non-Vacuum 56635

59026 6" Basic Vacuum 56636

59027 6" Deluxe Vacuum 56636

59028 6" Self Generated Vacuum 56636

59029 6" Central Vacuum 56637

59030 3-1/2" Non-Vacuum 56638

59031 3-1/2" Basic Vacuum 56639

59032 3-1/2" Deluxe Vacuum 56639

59033 3-1/2" Self Generated Vacuum 56639

59034 3-1/2" Central Vacuum 56640

59035 5" Non-Vacuum 56641

59036 5" Basic Vacuum 56642

59037 5" Deluxe Vacuum 56642

59038 5" Self Generated Vacuum 56642

59039 5" Central Vacuum 56643

Model Vacuum Housing

Number Description Number

59040 6" Non-Vacuum 56644

59041 6" Basic Vacuum 56645

59042 6" Deluxe Vacuum 56645

59043 6" Self Generated Vacuum 56645

59044 6" Central Vacuum 56646

59100 3" Non-Vacuum 56647

59101 3" Basic Vacuum 56648

59102 3" Deluxe Vacuum 56648

59103 3" Self Generated Vacuum 56648

59104 3" Central Vacuum 56649

59105 3" Non-Vacuum 56650

59106 3" Basic Vacuum 56664

59107 3" Deluxe Vacuum 56664

59108 3" Self Generated Vacuum 56664

59109 3" Central Vacuum 56665

59110 3" Non-Vacuum 56666

59111 3" Basic Vacuum 56667

59112 3" Deluxe Vacuum 56667

59113 3" Self Generated Vacuum 56667

59114 3" Central Vacuum 56668

Motor Assembly/Disassembly Instructions - Dynorbital-Spirit™

Important: Manufacturers warranty is void if tool is disassembled before warranty expires.

AFull Service Repair Kit P/N 57098, is available which includes special repair tools for correct disassembly/assembly of the sander.

To Disassemble:

1. Disconnect sander from air supply.

2. Invert the sander, and place the 57092 Repair Collar (supplied in the 57098 Full Service Repair Kit) around the housing and secure in a vise. Padding

can be used on the vise jaws to protect the housing. Important: Do not over tighten the sander in the vise. If the sander is held too tight the

removal of the lock ring and air motor will be difficult.

3. Remove sanding pad with the 50679 26 mm Open-end Wrench (supplied with the sander).

4. Insert 56058 Lock Ring Tool (supplied in 57098 Full Service Repair Kit) into the corresponding tabs of lock ring. Loosen the 59058 Lock Ring

turning it counterclockwise.

5. Remove the 59058 Lock Ring and the 50659 O-Ring from the air motor assembly (3/32" and 3/16" dia. orbits only).

6. Remove 01024 O-Ring and 98463 Retaining Ring from motor assembly.

7. Fasten a 2 in. bearing separator (P/N 96346 available) around the 59051 Cylinder just below the 59077 Rear Bearing Plate. Place the air motor

assembly in a #2 arbor press (P/N 96232 available) so that the separator is resting on the table of the arbor press and with the balancer pointing down.

8. Use a flat nose 3/16" dia. drive punch as a press tool. Place it against the small end of the motor shaft balancer and push the shaft out of the

upper 58368 Bearing.

9. Remove the rotor, vanes and rotor key from the motor shaft balancer.

10. Again fasten the 2 in. bearing separator between 58368 Bearing and the top of the balancer. Rest the separator on the table of the arbor press

and push the motor shaft balancer out of the 58368 Bearing. Remove 59057 “Top Hat” Seal and 59083 Felt from 59076 Front Bearing Plate.

11. Disassemble the balancer assembly as follows:

a.) Place motor shaft balancer assembly into a soft jaw vise. Using a thin screwdriver, pick out the end of 95630 Snap Ring and remove. This will

loosen the balancer assembly.

b.) Screw the threaded portion of the 56056 Bearing Puller (supplied in 57098 Repair Kit) into the 57069 Balancer Shaft and heat the outside of the

motor shaft balancer to approximately 200° F (approximately 10 seconds with a propane torch). Now, using the slider weight, pull

the assembly out.

c.) Press off 56052 Bearing with a bearing separator and arbor press remove 59084 V-Seal.

12. If during step 11, the 56052 Bearing remains in the motor shaft balancer, it can be removed by the heating the shaft balancer again and using either an

inside bearing puller or a blind hole bearing puller.

To Assemble:

Important: Clean and inspect all parts for defects before assembling.

1. Assemble the balancer assembly as follows:

a.) Install 59084 V-Seal onto the balancer shaft. Install with flexible lip of seal facing hex of balancer shaft. Be certain seal is pressed

completely over shaft step. See Drawing 1.

b.) Install 95360 Snap Ring between flange of 59084 V-Seal and hex of balancer shaft.

c.) Apply 1 drop of #271 Loctite®(or equivalent) and spread over several places around inside diameter of 56052 Bearing and the outside diameter

of the 57069 Balancer Shaft.

d.) Use the 57091 Bearing Press Tool to press 56052 Bearing with seal side toward hex of balancer shaft up to shaft step as shown in Drawing 1.

This is a firm press fit for proper retention of bearing.

2. Place the motor shaft balancer in a soft aluminum or bronze jaw vise with large end pointing up.

3. Apply 1 drop of #271 Loctite®(or equivalent) and spread over several places around the outside diameter of the 56052 Bearing and slide balancer

assembly into the motor shaft balancer until 56052 Bearing is firmly seated at bottom. Squeeze 95630 Snap Ring into groove in motor shaft balancer

to complete the assembly. Remove from vise. Place 50659 O-Ring and 59058 Lock Ring onto the motor shaft balancer (3/8" orbit models only).

4. Place the 59083 Felt into the 59057 “Top Hat” Seal.

5. Install the felt and the “Top Hat” Seal onto the motor shaft balancer so that they are centered as is shown in Drawing 2.

6. Use the small end of the 57091 Bearing Press Tool and the 96232 Arbor Press to install the 58368 Bearing onto the motor shaft balancer as

shown in Drawing 3.

7. Install the 59076 Front Bearing Plate onto the motor shaft balancer, fitting it to the bearing, felt, and “Top Hat” Seal as is shown in Drawing 4.

8. Install the rotor key and the rotor onto the motor shaft balancer.

9. Lubricate the 56073 Vanes with the 95842 DynabradeAir Lube (10W/NR or equivalent) and install them into the rotor.

10. Install the 59051 Cylinder so that the short line-up pin fits into the front bearing plate.

(continued on next page)

57091

Bearing Press Tool

Balancer ShaftAssembly

56052 Bearing

59084 V-Seal

Drawing 1

Balancer Shaft Assembly

Motor Shaft Balancer

59057 “Top Hat” Seal

59083 Felt Seal

Drawing 2

To Assemble (Continued):

11. Install the 58368 Bearing into the 59077 Rear Bearing Plate.

12. Use the small end of the 57091 Bearing Press Tool and the arbor press to install the rear bearing/plate onto the motor shaft balancer as is shown in

Drawing 5. Press the bearing/plate down until it touches the cylinder. This should create a snug fit between the bearing plates and cylinder.

13. Install the 01024 O-Ring into the cylinder and apply a small amount of the DynabradeAir Lube onto the o-ring.

14. Coat the 50659 O-Ring with the DynabradeAir Lube and install it into the 59058 Lock Ring. Slip these over the counter weight of the 3/32' and

the 3/16" orbit sanders.

15. Place a mark on the edge of the motor opening to identify the location of the line-up notch on the inside of the housing.

16. Install the motor assembly into the housing. Be certain that the line-up pin enters the notch in the housing.

17. Use the 57092 Collar to carefully hold the tool in a vise so that the counter balance is pointing up.

18. Use the 56058 Lock Ring Tool to tighten the 59058 Lock Ring by turning it clockwise. (Torque to 23 N•m/200 in.- lbs.)

19. Use the 26 mm open-end wrench to install a weight-mated sanding pad.

Valve and Speed Regulator Assemblies:

1. Secure housing in vice using 57092 Collar or padded jaws.

2. Remove inlet bushing, 01468 Spring, 58365 Tip Valve and 01464 Seal from housing. Remove 98927 Pin from housing and lever.

3. Remove 95697 Snap Ring. Press the speed regulator and valve stem out of the housing. Remove the 01025 O-Rings (2) and 98459 O-Ring.

4. Place new 01025 O-Rings (2) on the speed regulator and a new 98459 O-Ring on the valve stem. Then place inhousing with valve stem. Install new

95967 Snap Ring. Apply a small amount of pneumatic tool oil to valve o-rings.

5. Place new 01464 Seal in housing. Using tweezers or needle nose pliers, place the tip valve into housing so that the tip valve goes under the valve

stem. Place new 01468 Spring into housing so small end is towards tip valve.

6. Apply a small amount of #567 Loctite®(or equivalent) around the threads of the first inlet bushing and tighten into housing to 23 N•m/200 in. - lbs.

7. Install Lever on housing with 98927 Pin centered on housing.

Note: Motor should operate at between 11,000 and 12,000 RPM at 6.2 bar (90 PSIG). RPM should be checked with a tachometer. Before operating,

we recommend that 2-3 drops of DynabradeAir Lube P/N 95842 (or equivalent) be placed directly into the air inlet with throttle lever depressed. Operate the

machine for approximately 30 seconds before application to workpiece to determine if machine is working properly and safely and to allow lubricating

oils to properly dispense through machine.

Loctite®is a registered trademark of the Loctite Corp.

Disc Pad Change:

1. Insert 50679 Wrench on flats of 57069 Balancer Shaft and twist off sanding pad by hand.

2. With wrench still in place, hand tighten new pad on tool.

3. No need to remove shroud or overskirt.

Required Weight of Pads:

3" Models –– Use pad weighing 75g.

3-1/2" Models –– Use pad weighing 80g.

5" Models –– Use pad weighing 100g.

6" Models –– Use pad weighing 130g.

57091

Bearing Press Tool

Balancer ShaftAssembly

Motor Shaft Balancer

Front Bearing

Drawing 3

57091

Bearing Press Tool

Balancer ShaftAssembly

Motor Shaft Balancer

Front Bearing

Drawing 4

57091

Bearing Press Tool

Balancer ShaftAssembly

Motor Shaft Balancer

59076 Front Bearing Plate

(with 58368 Bearing)

59077 Rear Bearing Plate

(with 58368 Bearing)

59051 CylinderAssembly

(w/Rotor and Vanes)

Line-Up Pin

Drawing 5

Motor Assembly/Disassembly Instructions - Dynorbital-Spirit™

LEGEND

TPart included in 96510

Tune-up Kit

XType of wear, no other

comments apply.

LEasily lost. Care during

assembly/disassembly.

DEasily damaged during

assembly/disassembly.

R1 Replace each time tool is

disassembled.

R2 Replace each second

time tool is disassembled.

Parts Common to all Models:

Note: Please refer to page 4 of tool manual for specific part number.

Index Part Description Number High Wear Medium Wear Low Wear Non-Wear

# Number Required 100% 70% 30% 10%

1See Note Sanding Pad 1 X

257084 Vacuum Shroud 1 X

357089 Vacuum Lip-Seal Shroud 1 X

454458 3-1/2" Shroud (Non-Vac) 1 X

56051 5" & 6" Shroud (Non-Vac) 1 X

595630 Snap Ring 1 L

657069 Balancer Shaft 1 X

759084 V-Seal 1 T, X

856052 Bearing 1 T, X

9See Note Motor Shaft Balancer 1 X

10 98461 Key 1 T, X

56047 Key 1 T, X

11 59058 Lock Ring 1 X

12 50659 O-Ring 1 X

13 59057 “Top Hat” Seal 1 X

14 59083 Felt 1 T, X

15 58368 Bearing 2 T, X

16 59076 Front Bearing Plate 1 X

17 57113 Rotor/Blade Set 1 T, X

18 01024 O-Ring 1 T, X

19 59051 Cylinder 1 X

20 59077 Rear Bearing Plate 1 X

21 98463 Retaining Ring 1 T, D

22 95697 Retaining Ring 1 T, D

23 See Note Housing 1 X

24 See Note Throttle Lever 1 X

25 98927 Pin 1T, X

26 98459 O-Ring 1 T, X

27 58363 Valve Stem 1 T, X

28 58364 Speed Regulator 1 T, X

29 01025 O-Ring 2 T, X

30 01464 Seal 1 T, X

31 58365 Tip Valve 1 T, L

32 01468 Spring 1 T, L

33 01494 Inlet Bushing 1 X

Machine Exhaust Parts (Reference pg. 5 for your machines specific components.)

157083 VacuumAdapter 1 X

296197 Dowel Pin 1 L

357066 Muffler Body 1 X

495526 O-Ring 1 T, L

559088 Vacuum Nozzle 1 D

657067 Vacuum Tube 1 X

757093 VacuumAdapter 1 X

856027 Muffler Inserts 2 T, X

956028 Muffler Cap 1 T, L

Drop-in Motors

•

Allows a quick and easy replacement.

No motor adjustments needed.

59450 – 3", 3-1/2" Dia., 3/8" Orbit

59451 – 3", 3-1/2" Dia., 3/16" Orbit

59452 – 3", 3-1/2" Dia., 3/32" Orbit

59453 – 5" Dia., 3/8" Orbit

59454 – 5" Dia., 3/16" Orbit

59455 – 5" Dia., 3/32" Orbit

59456 – 6" Dia., 3/8" Orbit

59457 – 6" Dia., 3/16" Orbit

59458 – 6" Dia., 3/32" Orbit

Complete Repair Solution

Includes: 10 Pack of Drop-in Motors

59459 Repair Kit

59460 – 3", 3-1/2" Dia., 3/8" Orbit

59461 – 3", 3-1/2" Dia., 3/16" Orbit

59462 – 3", 3-1/2" Dia., 3/32" Orbit

59463 – 5" Dia., 3/8" Orbit

59464 – 5" Dia., 3/16" Orbit

59465 – 5" Dia., 3/32" Orbit

59466 – 6" Dia., 3/8" Orbit

59467 – 6" Dia., 3/16" Orbit

59468 – 6" Dia., 3/32" Orbit

10 Pack of Drop-in Motors

59470 – 3", 3-1/2" Dia., 3/8" Orbit

59471 – 3", 3-1/2" Dia., 3/16" Orbit

59472 – 3", 3-1/2" Dia., 3/32" Orbit

59473 – 5" Dia., 3/8" Orbit

59474 – 5" Dia., 3/16" Orbit

59475 – 5" Dia., 3/32" Orbit

59476 – 6" Dia., 3/8" Orbit

59477 – 6" Dia., 3/16" Orbit

59478 – 6" Dia., 3/32" Orbit

59459 Drop-in Motor Repair Kit:

Includes special tools for proper

disassembly/assembly of the

Dynorbital-Spirit™ drop-in motor.

Includes: 57092 Repair Collar

56058 Lock Ring Wrench

57098 Full Service Repair Kit:

Includes special tools for proper

disassembly/assembly of the

Dynorbital-Spirit™.

Includes: 57092 Repair Collar

56058 Lock Ring Wrench

56056 Bearing Puller

57091 Bearing Press Tool

57099 Bearing Puller

96034 12mm Hex Wrench

96510 Tune-Up Kit

• Tune-Up Kit contains high

wear and medium wear parts.

This service chart is published as a guide to expectant life of component parts. The replacement levels are based on average tool usage over one

year. Dynabrade Inc. considers one year usage to be 1,000 hours or 50% of a man year. Parts included in motor tune-up kit are identified by High

Wear and Medium Wear items.

Preventative Maintenance Schedule

For All Dynorbital-Spirit™ Sanders

Pad 3-1/2" 5" 6"

Description Dual Purpose Non-Vac Vac Non-Vac Vac

1/2" Thick, “Diamond Pattern Face” — 50630 50631 50632 50633

1/2" Thick, “Post Pattern Face” — — 50695 —50696

Random Orbital Sanding Pads

Perfectly balanced and weight-mated to Dynorbital®Spirit Random Orbital Sander.

Coated Abrasive Discs

Pad 3-1/2" 5" 6"

Description Dual Purpose Non-Vac Vac Non-Vac Vac

3/8" Thick, Soft Density — 56102 56100 56103 56101

3/8" Thick, Medium Density — 56106 56104 56107 56105

5/8" Thick, Soft Density 56097 56185 56186 56187 56188

5/8" Thick, Medium Density 56098 56175 56176 56177 56178

Premium Urethane Pad - Vinyl Face for PSA-Type Discs

Pad 3-1/2" 5" 6"

Description Dual Purpose Non-Vac Vac Non-Vac Vac

3/8" Thick, Soft Density — 56157 56155 56158 56156

3/8" Thick, Medium Density — 54325 54326 54327 54328

5/8" Thick, Soft Density 54311 56195 56196 56197 56198

5/8" Thick, Medium Density 54313 56180 56181 56182 56183

Premium Urethane Pad - Hook Face Short Nap Pads for Scrim-Back Discs

Rubber Pad, Medium Density - Vinyl Face Pads for PSA-Type Discs

Pad 3-1/2" 5" 6"

Description Dual Purpose Non-Vac Vac Non-Vac Vac

1/2" Thick, Medium Density 54314 50605 50607 50606 50610

Rubber, Medium Density - Hook Face Long Nap Pads for Non-Woven Nylon Discs

•Premium urethane pads, available in soft or medium density, resist heat build-up.

•New 5/8" thick pads, ideal for sanding of intricate contours.

•Unique vinyl surface pads provide excellent disc adhesion, allowing for quick removal of used discs.

•Special rubber/vinyl face pads for PSAdiscs.

•“Post Pattern” design for enhanced vacuum pick-up.

•Unique vinyl surface pads provide excellent disc adhesion, allowing for quick removal of used discs.

•No need to align vacuum holes, saves time on disc changes.

•Hook face “short nap” pads for reattachable discs.

•3-1/2", 5" and 6" diameter disc pads have 5/16"-24 male threaded stud.

•The 3-1/2" diameter discs, without holes, can be used on vacuum and non-vacuum 3-1/2" Dynorbital-Spirit™ Sanders.

•Hook face “long nap” pads forAbrasive Impregnated Non-Woven Nylon Discs.

Premium Aluminum Oxide Discs / PSA Mounted

Abrasive Grit

80 100 120 150 180 220 320

*No Holes 92090 – 92092 – 92094 92095 92097

No Holes 93101 93102 93103 93104 93105 93106 –

5-Hole Pattern 93109 93110 93111 93112 93113 93114 –

No Holes 93200 93201 93202 93203 93204 93205 –

6-Hole Pattern 93215 93216 93217 93218 93219 93220 –

Note: Other grits available upon request.

*Used on either vacuum or non-vacuum 3-1/2" sander.

All Discs: 120 Grit and Coarser – 125/Roll; 10 Rolls = Unit.

150 Grit and Finer – 175/Roll; 6 Rolls = Unit. Complete rolls only.

Disc

Type 3-1/2" Diameter

5" Diameter

6" Diameter

Disc

Type

Silicon Carbide Discs / PSA Mounted

Abrasive Grit

80 100 120 150 180 220

No Holes 93051 93052 93053 93054 93055 93056

5-Hole Pattern 93060 93061 93062 93063 93064 93065

No Holes 93069 93070 93071 93072 93073 93074

6-Hole Pattern 93077 93078 93079 93080 93081 93082

6" Diameter

Note: Other grits available upon request.

All Discs: 120 Grit and Coarser – 125/Roll; 8 Rolls = Unit.

150 Grit & Finer – 250/Roll; 4 Rolls = Unit. Complete rolls only.

5" Diameter

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