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Orbital Sander Service Instructions
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1. Revision 10 03 07 to lose the Plate and Muffler out of the exhaust before it is secured in one of the following steps NOTE If the machine is a CV SGV model proceed with the appropriate vacuum exhaust assembly instructions other wise move onto step 4 For CV Central Vacuum Exhaust machines A Attach the Snap In Exhaust Adapter B Take the 1 in 28 mm CV Swivel Exhaust Assembly or the in 19 mm CV Swivel Exhaust Assembly and put the tongue on the male end of it into the female end of the Snap In Exhaust Adapter With the swivel end of the Exhaust angled towards the ground work the tongue and male end into the female end of the Snap In Exhaust Adapter by rotating the swivel end up and in at the same time until it seats C Thread the Screw into the mounting hole of the 1 in 28 mm CV Swivel Exhaust Assembly or the in 19 mm CV Swivel Exhaust Assembly and Housing until the end of it is flush with the inside surface of the Housing Place the washer and Nut into the cavity of the Housing and thread the Screw into them until tight Move onto step 4 For SGV Self Generated Vacuum Exhaust machines A Attach the Snap In Exhaust Adapter B Lightly grease two O rings and place them over the two grooves in the SGV Retainer Assembly Slide the SGV Retainer Assembly into the bore of the 1 in 28 mm SGV Swivel Exhaust Assembly or the in 19 mm Hose SGV Swivel Exhaust Assembly C Attach th
2. SERVICE INSTRUCTIONS FOR 3 x 4 in 75 x 100 mm 3M 10 000 OPM ORBITAL SANDERS 3M Overhaul Service Kit The part number 20345 3M Overhaul Service Kit contains all the replacement parts that naturally wear over time and a straightforward manual to make servicing an 3M sander simple Overhauling the Orbital Sander can be made even easier with the use of the above Service Tools The Service Tools also reduce the chance of improper assembly Part Number Description Qty 3MA0040 EXTERNAL RETAINING RING 1 3MA0021 BEARING 2 SHIELDS 1 3MBO0005 ROTOR 1 3MA0010 VANE 5 3MA0041 WOODRUFF KEY 1 3MA0042 O RING 1 3MA0019 BEARING 2 SHIELDS 1 3MA0162 BEARING NO SEAL SHIELDS 1 3MA0196 SPACER 1 3MA0161 BEARING 1 SEAL 1 3MA0039 INTERNAL RETAINING RING 1 3MA0032 MUFFLER INSERT for 10 000 RPM Machines 2 3MA0009__ VALVE SEAT 1 3MA0007 VALVE 1 3MA0014 VALVE SPRING 1 3MA0043 O RING 1 3MC0018 MINI PAD SUPPORT 2 3MA0008 VALVE STEM ASSEMBLY 1 3MA0166 MUFFLER HOUSING 1 3MA1413 INSTRUCTIONS FOR 3 in X 4 in OS OVERHAUL SERVICE KIT 1 34 8700 5193 4 Revision 10 03 07 3 in x 4 in 75 x 100 mm Orbital Sanders Service Instructions NOTICE To receive any expressed or implied warranty the tool must be repaired by an authorized Service Center The 3 in x 4 in 75 x 100 Orbital Sander Service Instructions
3. e SGV Swivel Exhaust Assembly to the exhaust port of the Housing by means of the SGV Retainer As sembly and by taking the male end of the SGV Swivel Exhaust Assembly and placing it into the female end of the Snap In Exhaust Adapter Screw the SGV Retainer Assembly into the threaded exhaust port on the Housing with an 8 mm hex key Torque to 45 in Ibs 5 08 Nm Move onto the section Spindle bearing shield and Balancer Shaft Assembly 4 Place a clean Muffler in the Muffler Housing and screw the Muffler Housing into the exhaust port of the Housing Torque to 20 in Ibs 2 25 Nm Spindle bearing shield and Balancer Shaft Assembly 1 Place the T 2A Spindle Bearing Pressing Tool Base onto a flat clean surface of a small hand press or equivalent with the spindle pocket facing upward Place the Spindle into the spindle pocket with the shaft facing upward 2 Place the Washer on the Spindle shaft with the curve of washer facing out so that the outside diameter of the washer will contact the outer diameter of the Bearing Lay the Shim on the shoulder of the Spindle Place the Bearing one seal on the Spindle with the seal side toward the Washer NOTE Make sure that both the inner and outer races of the Bearings are supported by the Bearing Press Tool when pressing them into place Press the Bearing onto the shoulder of Spindle using the T 2B Spindle Bearing Pressing Tool Top as shown in Figure 3 3 Place the Shim over the Spindle sha
4. earing locker around the bearings until distributed evenly CAUTION Only a very small amount of bearing locker is needed to prevent rotation of the bearing OD Any excess will make future removal difficult Place the Spindle Assembly into the bore of the Shaft Balancer and secure with the Retaining Ring CAUTION Make sure that the Retain ing Ring is completely snapped into the groove in the Balancer shaft Allow the adhesive to cure Motor Assembly 1 Use the larger end of the T 13 Bearing Press Sleeve to Press the front Bearing with 2 Shields onto the shaft of the Shaft Balancer 2 Slide the Front Endplate with the bearing pocket facing down onto the Motor Shaft Gently press the Front Endplate onto the front Bearing using the larger end of the T 13 Bearing Press Sleeve until the front Bearing is seated in the bearing pocket of the Front Endplate CAU TION Only press just enough to seat the Bearing into the pocket Over pressing can damage the Bearing 3 Place the Key into the groove on the Shaft Balancer Place the Rotor on the Shaft Balancer making sure that it is a tight slip fit 4 Oil the Vanes with a quality pneumatic tool oil and place them in the slots in the Rotor Place the Cylinder As sembly over the Rotor with the short end of the Spring Pin engaging the blind hole in the Front Endplate NOTE The Spring Pin must project 060 in 1 5 mm above the flanged side of the Cylinder 5 Press fit the rear Bearing 2 shi
5. elds into the Rear End plate with the T 1B Bearing Press Tool Top Make sure the T 1B Press Tool is centered on the O D of the outer race Lightly press fit the Rear Endplate and Bearing over the Shaft Balancer using the small end of the T 13 Bearing Press Sleeve The sleeve should press only the inner race of the bearing IMPORTANT The Rear Endplate and Bearing is pressed correctly when the Cylinder is squeezed just enough between the Endplates to stop it from moving freely under its own weight when the shaft is held horizontal but be able to slide between the Endplates with a very light force If the assembly is pressed to tightly the motor will not run freely If the pressed assembly is to loose the motor will not turn freely after assembly in the Housing CAUTION If the Rear Endplate assembly is over pressed damage to the Front and Rear Endplate Bearings may result 6 Secure the assembly by placing the Retaining Ring in the groove of the Shaft Balancer CAUTION The Retaining Ring must be placed so that the middle and two ends of the hoop touch the Bearing first Both raised center por tions must be securely snapped into the groove in the 34 8700 5193 4 4 Shaft Balancer by pushing on the curved portions with a small screwdriver 7 Lightly grease the O Ring and place in the air inlet of the Cylinder Assembly 8 Lightly grease or oil the inside diameter of the Housing line up the Spring Pin with the marking on the H
6. etainer Assembly with an 8 mm hex key Remove the two O rings Take off the 1 in 28 mm SGV Swivel Exhaust Assembly or the in 19 mm Hose SGV Swivel Exhaust Assembly H Work off the Snap In Exhaust Adapter 2 Place the Speed Control to the midway position and remove the Retaining Ring The Speed Control will now pull straight out Remove the O Ring 3 Unscrew the Inlet Bushing Assembly from the Housing Remove the Valve Spring Valve Valve Seat Valve Stem with the O Ring Press out the Spring Pin from the Hous ing and remove the Lever ASSEMBLY INSTRUCTIONS NOTE All assembly must be done with clean dry parts and all bearings are to be pressed in place by the correct tools and procedures as outlined by the bearing manufacturers Housing Assembly 1 Install the Throttle Lever into Housing with the Pin 2 Lightly grease O Ring and place it on Speed Control Install Valve Stem O Ring cleaned and lightly greased and insert the Speed Control into Housing in the midway position Install Retaining Ring CAUTION Make sure the Retaining Ring is completely snapped into groove in the Housing 3 Install the Valve Seat the Valve and Valve Spring Coat the threads of the Bushing Assembly with 1 or 2 drops of 3M Rite Loc TL22 or equivalent non permanent pipe thread sealant Screw the assembly into the Housing Torque to 60 in Ibs 6 77 Nm Place a clean Muffler and Plate into the exhaust port of the Housing Be careful not
7. ew holes and placing the pad backing down onto the Spindle Assembly making sure the Pin goes through the Pad Backing Add the Screw first and tighten firmly In a circular rotation apply smaller Screws into the Pad Backing and Mini Pad Support Assemblies but leave them slightly loose until all are in place and then tighten firmly Attach a new Pad on the Pad Backing with the four Screws 1 1 N Testing Place 3 drops of quality pneumatic air tool oil directly into the motor inlet and connect it to a 90 psig 6 2 Bar air sup ply The tool should run between 9 500 and 10 000 Orbits per Minute when the air pressure is 90 psig 6 2 Bar at the inlet of the tool while the tool is running at free speed Revision 10 03 07 Troubleshooting Guide Symptom Possible Cause Check air line pressure at the Inlet of Insufficient Air Pressure the Sander while the tool is running at free speed It must be 90 psig 6 2 Bar See the Housing Disassembly section for Muffler removal Replace Muffler Blocked Muffler s Insert See the Housing Assembly Section Clean the Inlet Screen with a clean Plugged Inlet Screen suitable cleaning solution If Screen does not come clean replace it Install a complete set of new Vanes all vanes must be replaced for proper Worn or Broken Vanes operation Coat all vanes with quality pneumatic tool oil See Motor Disas Low Power and or Low Free 5 Speed sembly and P Mo
8. ft and onto the face of the Bearing making sure it is on center Press the no seals shields Bearing down using the T 2B Spindle Bearing Pressing Tool Top being careful to make sure the Shim is still centered on the vertical axis of the Spin dle shaft and Bearing See Figure 4 When the Spindle Assembly is done correctly the Bearings will rotate freely but not loosely and the Shim can be moved but will not slide or move by gravity 4 Snap the Retaining Ring not shown in Figure 3 or 4 onto the Spindle Assembly making sure it is completely snapped into the groove 5 Take the Filter and center it on the small bore that the original Filter was in before removal With a small diam eter screwdriver or flat ended rod press the Filter into the bore until it is flat in the bottom of the bore Place the Valve into the bore so it is oriented correctly then press the Retainer into the bore until it is flush with the bottom of the Bearing bore Bearing Press Tool Top KY g Bearing m o T 26 Shim oe ee Washer ee Se _ A PEN Spindle Press Tool Base E O l T 2A g Figure 2 Figure 3 Figure 4 34 8700 5193 4 3 Revision 10 03 07 6 Apply a pin head size drop of 3M Rite Loc TL71 or equiv alent to the outside diameter of each of the bearings on the spindle assembly Spread the drop of b
9. or central vacuum machines it is possible to have too much vacuum while sanding on a flat surface causing the pad to stick to the sanding surface Addition of interface pad or other material For CV machines reduce vacuum through the vacuum system 34 8700 5193 4 Revision 10 03 07
10. ousing and slide the Motor Assembly into the Housing Make sure the Pin engages the pocket in Housing 9 Carefully screw the Lock Ring into the Housing with the T 6 Motor Lock Ring Wrench Spindle Puller Tool Torque to 60 in Ibs 6 77 Nm NOTE A simple technique to assure first thread engagement is to turn the lock ring counter clockwise with the T 6 Motor Lock Ring Wrench Spindle Puller while applying light pressure You will hear and feel a click when the lead thread of the lock ring drops into the lead thread of the housing 10 Place one of the Mini Pad Support Assemblies into the Housing with the 45 degree chamfer of the base facing outward away from the center of the machine and the arc in the base of the pad support facing toward the cen ter of the machine Screw tight with the two Screws and Washers Repeat for second pad support Using a straight edge placed across both bottom sur faces of the Mini Pad Support Assemblies measure the distance from the surface of the Spindle Assembly to the straight edge There should be approximately 010 in 0 25 mm of space if not add supplied Spacers in the combination that most closely results in 010 in 0 25 mm of spacing NOTE Spindle face must be slightly below Mini Pad Supports for best function Do not over shim Apply a small amount of anti seize compound in the 5 90 c sink holes of the Pad Backing before assembly Place the Pad Backing by orientating the Shims with the scr
11. section provided is for use after completion of the warranty period DISASSEMBLY INSTRUCTIONS Changing Grips 1 The Grip has two tabs that wrap around the body of the sander under the inlet and exhaust With a small screw driver pick out one of the tabs of the Grip and then con tinue to go underneath the grip with the screwdriver and pry the Grip off the sander To install a new Grip hold the Grip by the tabs making them face outward align the Grip and slide it under the Throttle Lever then press the Grip down until it seats onto the top of the sander Make sure the two tabs seat under the inlet and exhaust Motor Disassembly 1 Remove the Pad from the machine by removing the four Screws Lightly secure tool in a vise using the T 7 Soft Collar or padded jaws with the bottom of the machine facing upward Remove the four Screws and then the Screw Remove the Pad Backing but be careful to ob serve and collect the optional Spacer s found between the Spindle Assembly and the Pad Backing 2 Take the machine out of the vise and take off the Soft Collar Remove the four Screws with the Washers from the Housing and remove the Mini Pad Supports Lightly re secure the tool in a vise using the T 7 Soft Collar or padded jaws with the Lock Ring facing upward 3 Remove the Lock Ring with the T 6 Motor Lock Ring Wrench Spindle Puller Tool Remove the O Ring from the Lock Ring and set it aside The motor assembly can now be lif
12. ssembly Use a Bearing Separator to remove the Bearing Shim Bearing Shim and the Washer from the Spindle As sembly 34 8700 5193 4 2 4 The bearing shield components are held in place by the light press fit of the Retainer These components can be damaged during removal and may need to be replaced if removed To remove the Retainer use an O ring pick or a 8 sheet metal screw to grip and pull out the Retainer Remove the Valve and Filter from the bore in the Shaft Balancer If the Retainer and Valve were not dam aged they can be reused However the filter should be replaced on re assembly Housing Disassembly 1 For Non Vacuum NV and Central Vacuum CV machines follow steps A C below unless otherwise noted For Self Generated Vacuum SGV machines disregard steps A F and move onto Step G below A Unscrew the Muffler Housing from the Housing B Remove the Muffler from the cavity of the Muffler Hous ing C Remove the Plate and second Muffler from the exhaust port of the Housing For Central Vacuum CV Exhaust machines D Remove the Screw Washer and Nut E Press downward on the swivel end of the 1 in 28 mm CV Swivel Exhaust Assembly or the in 19 mm CV Swivel Exhaust Assembly releasing the tab on the end of the exhaust assembly from the Snap In Exhaust Adapter F Work off the Snap In Exhaust Adapter Move on to step 2 For Self Generated Vacuum SGV Exhaust machines G Unscrew the SGV R
13. ted out of the Housing 4 Remove the Retaining Ring from the groove in the Shaft Balancer and the O Ring from the Cylinder 5 Remove the Rear Endplate This may require setting the Rear Endplate on a Bearing Separator and lightly press ing the shaft through the Bearing and Rear Endplate Remove the Cylinder and the Rotor with the five Vanes from the Shaft Balancer Remove the Key then press off the Front Endplate with the Bearing It may be necessary to remove the Bearing with a Bearing Separator if it came out of the Front Endplate and stuck to the shaft of the Shaft Balancer 6 Remove the Bearing s from the Endplates by using the T 8 Bearing Removal Tool to press out the Bearings Shaft Balancer and Spindle Disassembly 1 Grip the shaft end of the Shaft Balancer in a padded vise With a thin screwdriver pick out the slotted end of the Retaining Ring and peel out 2 Screw the female end of the T 12 5 16 24 to M6 x 1P Adapter into the male end of the T 6 Motor Lock Ring Wrench Spindle Puller Tool Screw the Service Wrench Assembly into the Spindle Assembly until hand tight Ap ply a gentle heat from a propane torch or hot air gun to the large end of the Shaft Balancer shaft until it is about 212 F 100 C to soften the adhesive Do not over heat Remove the Spindle Assembly by using the slider to give sharp outward blows to the Spindle Allow the Spindle and Shaft Balancer to cool 3 Remove the Retaining Ring from the Spindle A
14. tor Assembly Check for proper Motor alignment and Internal air leakage in the Motor Housing Lock Ring engagement Cheeks tor indicated by higher than normal air con damaged O Ring i iLock Ring groove y ng Remove Motor Assembly and Re Install sumption and lower than normal speed the Motor Assembly See Motor Disas sembly and Motor Assembly Motor Parts Worn Overhaul Motor Contact authorized Service Center Replace the worn or broken Bear ings See Shaft Balancer and Spindle Disassembly and Spindle Bearings Worn or broken Spindle Bearings Bearing Shield and Shaft Balancer Assembly Disassemble inspect and replace worn Dirty broken or bent Valve Spring Valve or or damaged parts See Steps 2 and 3 in Housing Disassembly and Steps 2 Air leakage through the Speed Control and or Valve Stem Valve Seat and 3 in Housing Assembly Only use Pad Sizes and Weights Incorrect Pad designed for the machine Only use abrasive and or interface designed for the machine Do not at tach anything to the Sanders Pad face that was not specifically designed to be used with the Pad and Sander Improper lubrication or buildup of foreign Dea emble me Sander anid cleanin debris a suitable cleaning solution Assemble the Sander See Service Manual eevee Worn or broken Rear or Front Motor Replace IG SO ar Broken Bearings Bearing s See Motor Disassembly and Motor Assembly F
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