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BELT SANDER

WARNING: Electrical repairs should only be attempted by trained repairmen. Contact the nearest PorterCable Service Center or other competent repair center.

504

PART NO. 697391 -

07-01-04

Copyright 2004 Porter-Cable Corporation

504

Ref. No.

1 1A 2 3 3A 3B 4 5 11 11A 12 15 15A 22 022 23 24 31 31A 33 33A 36 39 40 40A 51 52 53A 54A 57 61 64 65 65A 66 69 70 70A 84 89B 93 167 200 201 202 203 204 205 206 209 210 211 213 216 217 218 219 220 221 222 223 224 226 228

Part No. Description

863223** 801551 860980 824216 803483 873497 801851 875863 855221 879010 804211 872829 855193 861660** 841133** 801852 697364** 841133** 803614 803626 802274 824059 802382 838306 801291 838307 802250 802358 804531 695664 827269 857836 804557 803270 855532 803695 804311 804407 804247 690680 839766 803173** 842756** 803079** 804485 839279 804604 876108** 859511 803521 839052 802886 839053 839093 839094 908908** 839097 802969 839095 803317 803341 697404** 803357** 695303 803365 804674** 803467 803595 803607 804566 873982 803337 ARMATURE, 120V MOTOR HOUSING BAFFLE FIELD, 120V BRUSH BRUSH CAP BRUSH HOLDER SWITCH CORD, 120V COMM END BEARING FAN END BEARING DRIVE PULLEY BEARING INNER JACKSHAFT BEARING OUTER JACKSHAFT BEARING FAN SEAL, (LATE TYPE) FAN SEAL, (EARLY TYPE) PULLEY SEAL JACKSHAFT SEAL, (CURRENT UNITS) (1 3/8" O. D.) JACKSHAFT SEAL, (EARLY UNITS) (1 1/4" O. D.) WORM WORM GEAR DRIVE SPROCKET, T2 DRIVE SPROCKET, T1 DRIVEN SPROCKET, T2 DRIVEN SPROCKET, T1 - CF DRIVE CHAIN, T2 DRIVE CHAIN, T1 JACKSHAFT DRIVE PULLEY SHAFT SHAFT & LEVER ASSY FRAME ASSY., T2, INCL: REF. 262,263 FRAME ASSY., T1, INCL: REF. 262,263 MOTOR HOUSING JACKSHAFT COVER CHAIN COVER HANDLE SET GRILL FRAME PROTECTOR BAR DRIVE PULLEY IDLER PULLEY IDLER ARM, (CURRENT UNITS) GASKET, (LATE UNITS) GASKET, (EARLY UNITS) PLUG, 7/8" (LATE UNITS) PLUG, 3/4" (EARLY UNITS) (CF) JACKSHAFT PLUG KNOB CHAIN TENSION SPRING ADJUSTING SCREW SLEEVE SPRING HOUSING RELEASE PINION TENSION SPRING PINION PLATE RELEASE LEVER LEVER PIN SHOE ASSY., INCL.: REF. 241 & 270 FAN BEARING SEAL NUT OIL SLINGER (CF) BRONZE THRUST WASHER STEEL THRUST WASHER SLEEVE & PIN ASSY., (CURRENT UNITS) SLEEVE & PIN ASSY., (EARLY UNITS) SPACER, T2 ONLY IDLER PULLEY SEAL CAP SHOE COVERING CLAMP, (EARLY UNITS) COVER GASKET INNER BEARING SPACER FIELD LEAD SUPPORT JACKSHAFT COVER GASKET JACKSHAFT COVER SCREW WEAR BAR SCREW

Ref. No.

229 230 231 232 233 234 237 238 239 240 241 242 244 245 246 247 248 249 250 252 253 254 255 257 258 259 261 262 263 265 266 * * * *

803496 803157 804415 690671** 804424** 804301 802450 804660 801200 804360 882187 852310** 876384** 823254 801845 863393 801848 802764 857516 803336 824355 802350 839686 802433 849314 845083 844107 802695 801896 825615 882187 859090 867345** 862721** 803104 842323 802876

Part No. Description BRUSH HOLDER WASHER PLATE SCREW BELT TRACKING WASHER ADJUSTING SPRING DRIVE PULLEY KEY NUT, T2 NUT, T1 BOTTOM SCREW GRILL SCREW BRUSH HOLDER SCREW SWITCH MOUNTING SCREW 6-32 X 1/4" SCREW, (CURRENT UNITS) 6-32 X 3/8" SCREW, (EARLY UNITS) PULLEY NUT LOWER SCREW UPPER SCREW COVER SCREW HANDLE TOP SCREW SCREW SPRING HOUSING SCREW FIELD SCREW, CF BAFFLE SCREW LOCK WASHER HINGE PIN TERMINAL SWITCH GROUNDING TERMINAL GROUND WIRE SCREW CORD CLAMP SCREW SPEC. PLATE SCREW WEAR PLATE WEAR PLATE SCREW OIL INSTRUCTION PLATE HARDWARE KIT AXIAL FLOW FAN BRUSH HOLDER LEAD WRENCH HOLDER HEX WRENCH

ACCESSORIES: (OPTIONAL) * * * * * 270 * * ** 803442 GEAR OIL 5 1/2 OZ. 803443 GEAR OIL 1 GAL. 875914 CHAIN LUBRICANT 5 1/2 OZ. 875667 CHAIN LUBRICANT 4 LB. 697405 SEAL, SLEEVE, & PIN KIT (NEW STYLE SEAL 839040'** CORK SHOE COVERING USE WITH GRAPHITE PAD n 48118 GRAPHITE PAD NOT SHOWN SEE SERVICE NOTES

SERVICE NOTES

JACKSHAFT SEAL/SLEEVE & PIN

504

Beginning with Serial Number 051600, an improved jackshaft seal (Ref. 24) is used. The old seal was 1 ¼" O.D. The new seal is 1 3/8" O.D., necessitating a new sleeve & pin assembly (Ref. 217. Service package #697405 contains a new style seal and a new style sleeve and pin assembly (for use when updating an older tool to the improved seal. ARMATURE ­ EARLY TYPE #860955 Early armature #860955 is no longer available. When required, the unit must be converted to the current armature #863223. NOTE: Modified axial fan on new armature must be used with baffle as with original turbine fan. FRAME REPLACEMENT Currently supplied frame #827269 is now bored at a smaller diameter to accept current armature fan seal arrangement. Frame replacement on early models will require conversion to current armature # 863223, seal #861660, and collar sleeve #859511. Early Models REMOVE: Ref: 022 209 211 860955 841133 839097 839095 Armature Seal Washer Slinger Current Models ADD: Ref: 1 22 167 *** 863223 841133 839097 863624 Armature Seal Washer Sleeve ***#863624 sleeve3 reduces seal bore in early style frame #827269 to accept new seal. Press sleeve to stop in bearing bore of frame.

DRIVE/DRIVEN SPROCKETSAND DRIVE CHAIN (A3 ONLY) When replacing drive sprocket, driven sprocket, or drive chain, follow table listed below by serial and model numbers. Parts can only be used as sets. GEAR SETS Early Model A3's (prior to serial #37707) must have worm and gear replaced in sets to match #803614 worm with #803626 gear or #839050 worm with #839051 gear.

Drive Sprocket Drive Sprocket Drive Chain

DRIVE PULLEY KEY

Model A3, Serial #38068 thru #38659 #39010 thru #63234 804543 - CF 802274 804552 - CF

Model A3, Serial #63234 thru #69955 824059 824058 - CF 824060 - CF

Model A3, Serial #69956 and up, incl: all Model 504's 824059 838306 ­ CF 838307

Units with serial numbers #49623 through #51017 were built using two #841002 keys in the #802358 shaft (in place of the #804424 keys). If replacing keys in one of these units (S/N 49623 through 51017): Use key #841002. All service shafts #802358 will continue to use two #804424 keys. If replacing the #802358 shaft in one of these special units: two #804424 keys must also be installed. IDLER ARM, ADJUSTING SCREW, AND SPRINGS Early idler arm #803076 is no longer available. For improved tracking, multi-sub #803076 with idler arm #690680, adjusting spring #690671, tension screw #876108, and tension spring #802886. HARDWARE KIT Hardware Kit includes the following reference numbers for use when complete tear-down is required: 3, 3A, 23, 24, 69, 93, 213, 216, 219, 221, 226, 228, 231, 232, 234, 237, 240, 241, 244, 245, 246, 247, 248, 253, 254, 258, 259. FRAME BAFFLE REF. 208 This part is no longer required and should be discarded when making repairs. CORK & STEEL SHOE AND CLAMP - REFS. 206, 220, 241 & 270 The Cork and Steel Shoes Ref.s 206 & 270, are being glued together and the Clamp Ref. 220 is being eliminated. The new Shoe Assy. includes the new one piece shoe and the attaching hardware. The parts are totally interchangeable and can be serviced either way. The steel shoe will continue to be available until inventory is used up then will be subbed to the new Shoe Assembly. The cork shoe will continue to be available for use with the accessory graphite pad.

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