PD09_40_52438.qxd:Diamond Wheel Tool

1 hp Right Angle Cut-Off Tool
For
Parts Page Reorder No. PD09•40
Effective July, 2009
Supersedes PD05•12
ø 5" (127mm) Diamond Wheels
For Serial No. 08E1000A and Higher
Air Tool Manual – Safety, Operation and Maintenance
SAVE THIS DOCUMENT, EDUCATE ALL PERSONNEL
Model:
52438 –
–
–
–
12,000 RPM
1-1/4" Vacuum Port
w/Adjustable Cutting Depth
3/4" Arbor
FIND THE MOST CURRENT OFFERING OF SUPPORT DOCUMENTS AND ACCESSORIES @ WWW.DYNABRADE.COM
WARNING
Read and understand this tool manual before operating your air tool. Follow all safety rules for the protection of operating personnel
as well as adjacent areas. Always operate, inspect and maintain this tool in accordance with the American National Standards
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.
SAFETY LEGEND
WARNING
WARNING
Practice safety requirements. Work alert,
have proper attire, and do not operate tools under
the influence of alcohol or drugs.
Read and understand tool manual before
work starts to reduce risk of injury to
operator, visitors, and tool.
WARNING
WARNING
Ear protection to be worn when exposure to sound,
exceeds the limits of applicable Federal, State or
local statues, ordinances and/or regulations.
Eye protection must be worn at all times,
eye protection to conform to ANSI Z87.1.
WARNING
WARNING
Respiratory protection to be used when exposed to
contaminants that exceed the applicable threshold
limit values required by law.
Air line hazard, pressurized supply lines and flexible
hoses can cause serious injury. Do not use damaged,
frayed or deteriorated air hoses and fittings.
WARNING
Some dust created by sanding, grinding, drilling, and other construction activities contain chemicals known to cause cancer, birth
defects or other reproductive harm. Some examples of these chemicals are:
• Lead from lead-based paints
• Crystalline silica from bricks and cement and other masonry products
• Arsenic and chromium from chemically treated lumber
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well
ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.
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 altered from the original design without expressed written consent from Dynabrade, Inc.
Tool Intent: Right angle cut-off tools with diamond wheels are ideal for cutting and trimming fiberglass/composite materials.
Do Not Use tool for anything other than intended applications.
Do Not Use on materials that will generate spark.
Training: Proper care, maintenance, and storage of your air tools will maximize performance.
• Employer's Responsibility – Provide right angle cut-off tool with proper diamond wheel to operators with safety instructions and training for safe use of tools and accessories.
Accessory Selection:
• Use only metal cut-off wheels with diamond impregnated abrasive with 3/4" arbor hole.
• Abrasive/accessory RPM (speed) rating MUST be approved for AT LEAST the tool RPM rating.
• Before mounting an accessory, visually inspect for defects. Do not use defective accessories.
• Use only recommended accessories. Reference Dynabrade catalog and this tool manual.
• Follow tool specifications before choosing size and type of accessory.
• Only use recommended fittings and air line sizes. Air supply hoses and air hose accessories must have a minimum working pressure 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.)
(continued on next page)
OPERATING INSTRUCTIONS
Warning: Always wear eye protection. Operator of tool is responsible for following: accepted eye, face, respiratory, hearing and body protection.
• Always use wheel guard. Make sure it is positioned to best protect the operator and make sure it is securely fastened. Wheel guards that are worn, damaged or have
been subject to a wheel breaking must be replaced.
Caution: Hand, wrist and arm injury may result from repetitive work, motion and overexposure to vibration.
• Tool RPM must never exceed abrasive/accessory RPM rating. Check accessory manufacturer for details on maximum operating speed or special mounting instructions.
• Keep hand and clothing away from working end of the air tool.
• Be sure that any loose clothing, hair and all jewelry is properly restrained.
• Check air hose and connecting fittings for condition. Repair worn or damaged parts.
• Secure inlet bushing on air tool with a wrench before attempting to install the air fitting to avoid damaging housing assembly.
• BEFORE MOUNTING A DIAMOND WHEEL, after all tool repairs and whenever a cut-off tool is issued for use, 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.
Diamond Cut-Off Wheel Mounting
With power source disconnected from the air tool.
Side View
Right Angle Housing
Remove wing thumb screw from guard and rotate shoe assembly to expose spindle.
Clean spindle and flange mounting surfaces. Inspect flanges for nicks, cuts and sharp edges. (Replace damaged flanges)
Cut-Off Guard
Use only Dynabrade flanges.
Driving Flange
Install drive flange with raised center boss facing outward.
Diamond
w/ Raised
Inspect diamond wheel for any damage, warpage or excessive wear before mounting. (Do not use defective diamond wheels)
Impregnated
Center Boss
Check for flange flatness and runout by rotating spindle and drive flange together.
Steel Wheel
Install diamond cut-off wheel over spindle thread and over raised center boss on flange.
Install outer flange nut with recessed face facing toward diamond cut-off wheel and secure flange firmly against the wheel.
Check diamond cut-off wheel to make sure it is properly tightened down.
Outer Flange Nut
Caution: Over tightening the outer flange nut can cause damage to the wheel and/or flanges.
Spindle
• Swing shoe assembly back into position and secure wing thumb screw.
• 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, make sure that no one is in the unguarded plane of the wheel before starting the tool. IN A PROTECTED AREA, test run the wheel 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. Test wheel at its free speed (RPM) in a protected area for at least one minute
before applying the wheel to the work.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Make sure that work area is uncluttered, and visitors are at a safe range from the tools and debris.
Guard Arrow Indicates Cut Direction
Air tools are not intended for use in explosive atmospheres and are not insulated for contact with electric power sources.
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.
Ensure that sparks and debris resulting from work does not create a hazard.
This tool is rear exhaust. Exhaust may contain lubricants, vane material, bearing grease, and other materials flushed through the tool.
When cutting-off, the workpiece shall be so supported that the slot is kept at constant or increasing width during the whole operation.
If the diamond wheel gets jammed in a cut slot, shut off the tool and ease the wheel free. Check that the wheel is still correctly secured and not damaged before
continuing the operation.
• A cut-off wheel shall not be used for side grinding.
Warning: Cutting certain materials can create explosive dust. It is the employer's responsibility to notify the user of acceptable dust levels.
• Certain materials can cause sparks which can cause fires or explosions. It is the user's responsibility to make sure the work is done on spark free materials.
Report to your supervisor any condition of the tool, accessories, or operation you consider unsafe.
Air System
Regulator
LUBRICATOR SETTING
Filter
1 DROP/MIN.
Lubricator
20 SCFM
Air Flow
➤
➤
Closed Loop Pipe System
(Sloped in the direction of air flow)
90 PSIG
(6.2 Bar)
To Tool Station
Regulator
Refrigerated
Air Dryer
Lubricator
➤
➤
Filter
➤
Drain
Valve
Drain
Valve
Air Hose
Ball
Valve
➤
• Dynabrade Air 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.
Ball
Valve
Air Flow
Air Tool
• Ideally the air supply should be free from moisture.
To facilitate removing moisture from air supply, the
installation of a refrigerated air dryer after the
compressor and the use of drain valves at each
tool station is recommended
Air Compressor
and Receiver
2
90 PSIG MAX
(6.2 Bar)
Drain Valve
Maintenance Instructions
Important: To keep tool safe a Preventative Maintenance Program is recommended whenever portable power tools are used. The program should include
inspection of air supply lines, air line pressure, proper lubrication and repair of tools. Refer to ANSI B186.1 for additional maintenance information.
• Use only genuine Dynabrade replacement parts to insure quality. To order replacement parts, specify Model#, Serial# and RPM of your air tool.
• It is strongly recommended that all Dynabrade rotary vane air tools be used with a Filter-Regulator-Lubricator to minimize the possibility of misuse due
to unclean air, wet air or insufficient lubrication. Dynabrade recommends the following: 10681 Air Filter-Regulator-Lubricator (FRL) – Provides accurate
air pressure regulation and two stage filtration of water contaminates.
• Lubricate wick system through the angle gear oil fitting with 2-3 plunges for every 24 hours of use, to achieve maximum gear life. Important: Use only
the recommended angle gear oil for the wick system. Do not contaminate the wick with any other oil or grease product (order 95848 Gear
Oil and 95541 Gun).
• 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). Dynabrade Air Lube (P/N 95842: 1 pt 473 ml) is recommended.
Routine Preventative Maintenance:
• Check free speed of tool using a tachometer. This governor controlled tool should be speed checked every 20 hours of use or weekly, whichever
occurs more frequently.
• DO NOT disassemble the governor for any reason. Reorder correct speed – governor assembly (See Assembly Breakdown) and recheck free speed of
tool with a tachometer.
• Inspect flanges regularly for nicks, cuts, sharp edges, flatness and runout. Replace damaged or worn flanges with genuine Dynabrade flanges.
• Inspect wheel guard for wear or damage. Guards that are bent and severely worn or subject to a wheel breakage must be replaced.
• Inspect cut-off wheel before mounting. Do not mount wheels that are damaged or warped.
• Check cut-off wheel - speed rating. Rating on wheel must be greater than the tool speed marked on the housing.
• If cut-off wheel damage occurs, investigate to determine the cause and correct before issuing tool for work.
• 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®).
• A Motor Tune-Up Kit (P/N 96532) is available which includes high wear and medium wear motor parts.
• Air tool labels must be kept legible at all times, if not, reorder label(s) and replace. User is responsible for maintaining specification information i.e.:
Model #, S/N, and RPM. (See Assembly Breakdown)
• 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 Dynabrade Air Lube (P/N 95842) to the air line and start the tool a few times to lubricate air motor.
Check for tool vibration before mounting abrasive wheel accessory.
Handling and Storage:
• Use of tool rests, hangers and/or balancers is recommended.
• Protect tool inlet from debris (see Notice below).
• DO NOT carry tool by air hose or near the tool throttle lever.
• Protect cut-off wheel from exposure to water, solvents, freezing temperature and extreme temperature changes. – See Manufacturer's Instructions –
• DO NOT USE cut-off wheels that have been dropped or show signs of warpage, cracks, nicks or other defects.
• Store accessories in protective racks or compartments to prevent damage.
Machine Specifications
Model
Number
Motor
hp (W)
Tool
RPM
Sound
Level
Air Flow Rate
SCFM (LPM)
Air Pressure
PSIG (Bars)
Wheel
Diameter
Weight
Pound (kg)
Length
Inch (mm)
52438
1 (746)
12,000
83 dB(A)
40 (1138)
90 (6.2)
5"
6.7 (3.0)
14-5/8 (372)
Height
Inch (mm)
4-1/2 (114)
Additional Specifications: Air Inlet Thread 3/8" NPT • Hose I.D. Size 3/8" or 10mm • Air Flow Rate Based At Max HP. • Air Pressure 90 PSIG Max
Notice
All Dynabrade motors use the highest quality parts and metals 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.
Lifetime Warranty
All Dynabrade portable pneumatic power tools are rigorously inspected and performance tested in our factory before shipping to our customers. If a
Dynabrade tool develops a performance problem and an inherent defect is found during normal use and service, Dynabrade will warrant this tool against
defects in workmanship and materials for the lifetime of the tool. Upon examination and review at our factory, Dynabrade shall confirm that the tool qualifies
for warranty status, and will repair or replace the tool at no charge to the customer. Normally wearable parts and products are NOT covered under this
warranty. Uncovered items include bearings, contact wheels, rotor blades, regulators, valve stems, levers, shrouds, guards, O-rings, seals, gaskets and other
wearable parts. Dynabrade’s warranty policy is contingent upon proper use of our tools in accordance with factory recommendations, instructions and safety
practices. It shall not apply to equipment that has been subjected to misuse, negligence, accident or tampering in any way so as to affect its normal
performance. To activate lifetime warranty, customer must register each tool at www.dynabrade.com. Dynabrade will not honor lifetime warranty on
unregistered tools. A one-year warranty will be honored on all unregistered portable pneumatic power tools. Lifetime warranty applies only to portable
pneumatic tools manufactured by Dynabrade, Inc. in the USA. Lifetime warranty applies only to the original tool owner; warranty is non-transferable.
3
Model:
1 hp Right Angle Cut-Off Tool for 5" Diamond Wheels
52438
Complete Assembly
Index Key
No.
Part # Description
1
2
3
4
5
6
7
8
9
10
11
12
13
53625
53658
53689
50963
53609
53611
97679
97678
97677
97676
53637
53608
53600
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
5" Cut-Off Guard – Vacuum
Outer Flange Nut
Drive Flange (w/raised boss)
Retainer
Shaft Seal
Spindle 3/8"-24
Bearing
Shim (.010" Thick)
Shim (.003" Thick)
Shim (.001" Thick)
Gear Set
Wick
Right Angle Housing Assy.
Includes the following:
A 96325 Shell Bearing
B 53649 Gear Oil Plate
C 01041 Gear Oil Fitting
53163 Side Handle
01266 Bearing
53635 Pinion Adapter
51969 Coupler Nut (2)
50902 Coupler
53650 Lock Ring
53651 Spacer
96498 Wave Spring
95438 O-Ring
53620 Adapter
54520 Bearing
51951 Shim Pack
51922 Front Bearing Plate
96441 Pin (2)
51927 Spacer
51921 Rotor
51926 Blade (4/Pkg.)
51925 Cylinder
51923 Rear Bearing Plate
02057 Bearing
96445 Pin (2)
51924 Gasket
51932 Governor Assembly
All Housings Include:
Warning & Specification Labels
20070 Housing – Model 52438
96444 Pin
51949 Safety Lever Assembly
51946 Valve Stem Assembly
(Incl. 96443 O-Ring)
51945 Valve Seat
51944 Tip Valve
51943 Spring
96442 O-Ring
51940 Spacer
53682 Gasket - Standard
53687 Gasket - For use with overhose
94528 Felt Silencer
53686 Muffler Cap
94924 Wave Spring
53683 Spacer
53681 Inlet Bushing
(Incl. 2 – 51938 Screens)
A8 T
52 00001248
53 00001181
A
C
5
3
B
2
11
9
8
6
1
4
A10 T
A8
W1
17 N•m
18
13
T
17
11
16
15
T
21
20
19
35 N•m
17 N•m
14
30
26
28
24
23
31
O1
29
27
25
17
T
17 N•m
39
22
40
2 N•m
T A10
A8
37
41
42
38
53
36
35
34
33
32
27
52
T
35 N•m
51*
O1
48*
Description
Warning Label
Specification Label
12
7
Label Key
No. Part #
W1
10
35 N•m
43
44*
45*
49*
50*
A10
47*
46*
Note: All index numbers with an asterisk
are included in P/N 53655 Muffler Assembly.
4
KEY
O
Oil: O1 = Air Lube
A
Adhesive: A8 = Loctite #567
A10 = Loctite #243
T
Torque: N•m x 8.85 = In. - lbs.
W
Wicking: W1 = Gear Oil
Disassembly Instructions - 1 hp Right Angle Cut-Off Tool for 5" Diamond Wheels
Important: Manufacturing Warranty is void if tool is disassembled before warranty expires. Please refer to complete part list for part identification.
Disconnect tool from power source before tool repair.
Right Angle Head Disassembly:
1. Remove side handle, outer flange, cut-off wheel and drive flange.
2. Remove guard assembly.
3. Secure 53600 Right Angle Housing, against both side handle bosses, in a padded vise with spindle facing upward.
4. Using 97782 Pin Wrench (ordered separately) or an adjustable pin wrench, remove 50963 Retainer. (Left Hand Threads)
5. Remove 53609 Shaft Seal from spindle or retainer.
6. Pull spindle and gear assembly from housing.
7. Press spindle through 97679 Bearing and spiral bevel gear.
8. Remove shims and 53608 Wick from right angle housing.
9. Remove 53650 Lock Ring from right angle housing (Left Hand Threads) and from motor housing (Right Hand Threads).
10. Remove angle head from vise and remove 96325 Bearing by pressing 53649 Gear Oil Plate through housing.
11. Pull pinion gear, bearing and coupler sub-assembly from angle housing.
12. Secure pinion gear wrench flats and remove the 51969 Coupler Nut (twist counterclockwise).
13. Secure 53635 Adapter using 95049 3/16" Hex Key Wrench and remove pinion gear (twist counterclockwise).
14. Press 53635 Adapter through 01266 Bearing.
Right Angle Head Disassembly Complete.
Motor Disassembly:
1.
2.
3.
4.
Remove 53651 Spacer and 96498 Wave Spring from housing assembly.
Pull motor assembly from housing, and remove 53620 Motor Adapter with 95438 O-Ring.
Remove governor assembly by using a slotted screwdriver. (Left Hand Threads)
Using 96209 Repair Clamp (ordered separately) secure 51925 Cylinder and place a 1/16" (1.5mm) drift pin to the base of the terminal thread and
press the 51921 Rotor from the 02057 Rear Bearing.
5. Slide 02057 Rear Bearing from 51923 Rear Bearing Plate.
6. Remove 51925 Cylinder and 51926 Blades.
7. Secure 51921 Rotor in padded vise and remove 51969 Coupler Nut (twist counterclockwise).
8. Slide 51922 Front Bearing Plate and 51927 Rotor Spacer from 51921 Rotor.
9. Slide 54520 Bearing and shims from 51922 Front Bearing Plate.
Motor Disassembly Complete.
Housing Disassembly:
1. Secure housing using 51989 Repair Collar (see back cover for Optional Accessories).
2. Remove inlet bushing with muffler assembly (twist counterclockwise).
3. Remove 53682 Gasket, 51943 Spring, 96442 O-Ring, 51940 Spacer, 94528 Felt Silencer, 53686 Muffler Cap, 94924 Wave Spring and 53683 Spacer
from 53681 Inlet Bushing.
4. Remove 51944 Tip Valve and 51945 Valve Seat.
5. Remove housing and 51989 Repair Collar and lay collar on bench with flange facing down so it is supporting throttle lever. Place a 3/32" (2.4mm) drift pin on
96444 Pin and tap pin thru housing.
6. Remove 51946 Valve Stem Assembly.
7. Remove 96443 O-Ring from 51946 Valve Stem Assembly.
Housing Disassembly Complete.
Assembly Instructions - 1 hp Right Angle Cut-Off Tool for 5" Diamond Wheels
Motor Assembly:
Important: Be sure parts are clean and in good repair before assembling. Follow oil, lubrication,adhesive and torque specifications.
1. Place 51921 Rotor into a padded vise with male thread facing upwards.
2. Slip 51927 Rotor Spacer over rotor shaft and down against rotor body face.
3. Press 96441 Coiled Pin into 51922 Front Bearing Plate. Make certain, coiled pin does not protrude beyond internal bearing surface.
4. Place a .002" (.05mm) shim into the base of 51922 Front Bearing Plate as an initial spacing and slide 54520 Bearing to the front plate base.
Note: 51951 Shim Pack contains 001" (.03mm) and .002" (.05mm) shims.
5. Slip bearing/bearing plate assembly onto rotor. Add one drop of Loctite® #243 (or equiv.) to 51921 Rotor 3/8"-24 male thread and screw 51969 Coupler
Nut into place. Torque to 17 N•m/150 lb. in.
6. Check clearance between rotor and front bearing plate by using a .001" feeler gauge. Clearance should be between .001" (.03mm) – .0015" (.04mm).
Adjust clearance by repeating steps 4 and 5 with different shims if necessary.
7. Once proper rotor gap clearance is achieved, install well lubricated 51926 Blades (4) into rotor slots. Dynabrade recommends lubricating blades with
95842 Air Lube.
8. Install 51925 Cylinder over rotor and front plate raised boss. Align coiled pin on front plate to cylinder slot.
9. Press 96441 Coiled Pin into blind hole on 51923 Rear Bearing Plate. Press (2) 96445 Coiled Pins into the back side of rear bearing plate.
10. Peel backing off 51924 Gasket and apply it firmly in place onto 51923 Rear Bearing Plate.
11. Place 51923 Rear Bearing Plate over rotor mandrel and insert raised boss on rear bearing plate into cylinder diameter, while inserting short coiled pin
into cylinder slot. Be sure inlet slot on rear bearing plate line up with inlet slot on cylinder. To correct alignment flip cylinder end to end and repeat
steps 8 & 9 for correct assembly.
12. Using 96243 Bearing Press Tool (ordered separately) press 02057 Bearing onto rotor and into 51923 Rear Bearing Plate hole until it is seated.
Important: Cylinder must fit snug between bearing plates. If too tight, rotor will not turn freely. Rotor must be lightly tapped at press fit end until rotor
spins freely while still maintaining a snug fit. A loose fit will not achieve the proper preload on motor. While pressing 02057 Bearing, make certain to
contact inner race of bearing
5
(continued on next page)
Assembly Instructions - (Continued)
13. Add one drop of Loctite #243 (or equiv.) to governor assembly male thread and screw governor assembly into place (Left Hand Threads) with a
slotted screwdriver. Torque to 2 N•m/18 lbs. in.
14. Install motor assembly into housing, making sure motor drops all the way into housing. Note: Align both 96445 Coiled Pins to slots in insert and
against 51924 Gasket.
15. Install 95438 O-Ring onto 53620 Adapter and slide adapter into housing and over 54520 Bearing.
16. Place 96498 Wave Washer onto 53620 Adapter.
17. Place 50902 Coupler into 51969 Coupler Nut.
®
Motor Assembly Complete.
Right Angle Head Assembly:
1. Press 01041 Gear Oil Fitting into 53649 Gear Oil Plate and insert sub-assembly into right angle housing.
2. Press 96325 Bearing into housing until it is firmly seated against 53649 Gear Oil Plate. Important: While pressing 96325 Bearing, make certain press
tool is similar in size to the outside diameter of the bearing.
3. Add one drop of Loctite® #243 (or equiv.) to male thread of 53635 Adapter and thread pinion using a 95049 3/16" Hex Key Wrench and the pinion
wrench flats until pinion bottoms on adapter. Unthread pinion from adapter for one full revolution.
4. Using 96244 Bearing Press Tool (ordered separately) press 53635 Adapter into 01266 Bearing. Important: While pressing 01266 Bearing, make
certain to contact inner race of bearing only.
5. Add one drop of Loctite® #243 (or equiv.) to male thread of adapter and tighten 51969 Coupler Nut both sets of using wrench flats. Torque to 17 N•m/150 lbs. in.
6. Insert sub-assembly into male threaded end of 53600 Right Angle Housing.
7. Apply a small amount of Loctite® #567 (or equiv.) to 53600 Right Angle Housing thread, and install 53650 Lock Ring (Left hand Threads).
8. Insert 53651 Spacer, with long length first, into 53650 Lock Ring and up against 01266 Bearing.
9. Apply a small amount of loctite® #567 (or equiv.) to male thread of motor housing.
10. Align 50902 Coupler onto 51969 Coupler Nut in R/A head assembly.
11. Thread motor housing into 53650 Lock Ring (twist clockwise).
12. Secure 53600 Right Angle Housing, against both side handle bosses, in a padded vise.
13. Rotate motor housing and 53650 Lock Ring until throttle lever is located inline with side handle feature. Throttle lever in this position safe guards against
accidental start ups of the tool. Torque lock ring to 35 N•m/310 lbs. in.
14. Place well lubricated 53608 Wick against 96325 Bearing with flat edge towards pinion gear. (Wick must be completely saturated with Dynabrade 95848
Gear Oil before installation). Note: Do not contaminate wick with any other oil or grease product.
15. Press 97679 Bearing onto spindle and against shoulder. Important: While pressing 97679 Bearing, make certain to contact inner race of bearing only.
16. Press gear, with teeth facing away from bearing, onto spindle and against 97679 Bearing inner race.
17. Insert spindle assembly into 53600 Right Angle Housing until 97679 Bearing contacts housing shoulder.
18. Rotate Spindle while pressing down into housing to check for gear alignment and backlash. Install shims as required (minimum backlash is recommended
for maximum gear life. Make certain there is clearance throughout 360˚ revolution).
19. Slide 53609 Felt Seal into 50963 Retainer.
20. Apply a small amount of Loctite® #567 (or equiv.) to the male thread of the retainer and thread into place (Left Hand Threads).
21. Using 97782 Pin Wrench (ordered separately) or an adjustable pin wrench. Torque retainer to 35 N•m/310 lbs. in.
22. Secure safety guard assembly firmly in place after orienting guard position to best protect the operator.
23. Install 53689 Drive Flange with raised center boss facing outward.
24. Install diamond cut-off wheel over spindle thread and over raised boss on drive flange.
25. Install outer flange with recess facing toward diamond cut-off wheel and secure flange firmly against the wheel.
Caution: Tighten flange only enough to prevent diamond cut-off wheel from spinning under working conditions. Over tightening the flange can
cause damage to the wheel and/or flanges.
Housing Assembly:
1. Secure housing using 51989 Repair Collar (see back cover for Optional Accessories) with inlet facing upward.
2. Slide 96443 O-Ring onto 51946 Valve Stem and slide sub-assembly until o-ring passes through housing hole. Make certain valve stem assembly slides
freely after the o-ring passes through the hole.
3. Install 51945 Valve Seat by aligning 3 male prongs with three deep slots on insert. Make certain valve seat is pressed flat against base of pocket.
Note: Add a few drops of Dynabrade Air Lube (P/N 95842) to pocket walls before inserting 51945 Valve Seat.
4. Install 51944 Tip Valve as shown.
5. Pre-assemble muffler, slide 53683 Spacer over 53681 Inlet Bushing and up against the hex head base. Slide 94924 Wave Spring over 53681 Inlet
Bushing and up against spacer. Pre roll 94528 Felt and install it in 53686 Muffler Cap. Support felt in felt/muffler cap assembly and slide 53681 Inlet
Bushing thru the inside until the muffler cap assembly seats against the 94924 Wave Spring. Flare the felt and place 51940 Spacer over male thread and
set 96442 O-Ring into groove at the base of thread. Return felt to unflared form. Slide 51943 Spring into bushing and up to the two 51938 screens.
6. Place 53682 Gasket over felt silencer and against 53686 Muffler Cap.
7. Apply one drop of Loctite® #243 (or equiv.) to 53681 Inlet Bushing Thread.
8. Align small inside diameter of 51943 Spring to cone point on 51944 Tip Valve and thread inlet bushing and sub-assembly into place. Torque
bushing to 35 N•m/310 lbs. in.
9. Remove housing from 51989 Repair Collar and place repair collar onto the bench top with the part number identifier against the bench. Align the throttle
lever holes to housing pinhole and rest the housing and throttle lever onto the legs of the repair collar. Press 96444 Coiled Pin into lever hole
and center into housing.
Tool Assembly Complete. Please allow 30 minutes for adhesives to cure before operating tool.
Important: Before operating, place 2-3 drops of Dynabrade Air Lube (P/N 95842) directly into inlet with throttle lever depressed. Operate tool for 30 seconds
to allow air lube to properly lubricate internal motor components. Motor should now be tested for proper operation at 90 PSIG max. If tool operates at a
higher RPM than marked on the tool or if vibration and sound levels seem abnormal, the tool should be serviced to correct the cause before use.
6
Preventative Maintenance Schedule
For All 1 hp Right Angle Cut-Off Tools with ø 5" (127mm) Diamond Cut-Off Wheels
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.
Parts Common to all Models:
LEGEND
T
Included in Tune-up Kit
X
Type of wear, no other
comments apply.
L
Easily lost. Care during
assembly/disassembly.
D
Easily damaged during
assembly/disassembly.
R
Replace each time tool is
disassembled.
96532 – 1 hp. Motor Tune-Up Kit
Index Part
# Number
1 53625
2 53658
3 53689
4 50963
5 53609
6 53611
7 97679
8 97678
9 97677
10 97676
11 53637
12 53608
13 53600
A 96325
B 53649
C 01041
14 53163
15 01266
16 53635
17 51969
18 50902
19 53650
20 53651
21 96498
22 95438
23 53620
24 54520
25 51951
26 51922
27 96441
28 51927
29 51921
30 51926
31 51925
32 51923
33 02057
34 96445
35 51924
36 51932
37 20070
38 96444
39 51949
40 51946
41 51945
42 51944
43 51943
44 96442
45 51940
46 53682
47 94528
48 53686
49 94924
50 53683
51 53681
Description
Number High Wear Medium Wear Low Wear
Required
100%
70%
30%
5" Cut-Off Guard - Vacuum
1
Outer Flange Nut
1
Drive Flange
1
Retainer
1
Shaft Seal
1
R
Spindle
1
Bearing
1
X
Shim (.010" Thick)
1
Shim (.003" Thick)
1
Shim (.001" Thick)
1
Gear Set
1
X
Wick
1
X
Right Angle Housing Assy.
1
Shell Bearing
1
X
Gear Oil Plate
1
Gear Oil Fitting
1
Side Handle
1
Bearing
1
X
Pinion Adapter
1
Coupler Nut
2
Coupler
1
X
Lock Ring
1
Spacer
1
Wave Spring
1
T
O-Ring
1
Adapter
1
Bearing
1
T
Shim Pack
1
L
Front Bearing Plate
1
X
Pin
2
X
Spacer
1
T
Rotor
1
X
Blade (4/pkg.)
1
T
Cylinder
1
X
Rear Bearing Plate
1
X
Bearing
1
T
Pin
2
X
Gasket
1
T
Governor Assembly
1
Housing
1
Pin
1
T
Safety Lever Assembly
1
X
Valve Stem Assembly
1
T
Valve Seat
1
Tip Valve
1
T
Spring
1
O-Ring
1
T
Spacer
1
Gasket
1
Felt Silencer
1
T
Muffler Cap
1
Wave Spring
1
Spacer
1
Inlet Bushing
1
Note: Please refer to page 4 of tool manual for specific part number.
7
Non-Wear
10%
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
T
X
X
X
X
X
X
X
X
X
X
X
Optional Accessories
FIND THE MOST CURRENT OFFERING OF SUPPORT DOCUMENTS AND ACCESSORIES @ WWW.DYNABRADE.COM
Dynaswivel ®
• Swivels 360° AT TWO PIVOT POINTS allowing the air hose to
drop directly to the floor while providing superb tool handling.
95461 – 3/8" NPT.
51989 Repair Collar
• Specially designed collar for use in vise to prevent damage
to valve body of tool during disassembly/assembly.
96532 Motor Tune-Up Kit
• Includes assorted parts to help maintain
and repair motor.
01902 Drop-In Motor
• Allows quick and easy replacement.
No motor adjustments needed.
53621 Overhose Assembly
• Overhose Assembly directs exhaust
away from operator.
Composite-Style Coupler
• Lightweight 1.4 oz. (.05 Kg), non-marring
composite material.
• Easy connect/disconnect by single
push-button action.
• Shock-proof, low-vibration, crush-resistant.
94960: 1/4" Female NPT
94980: 1/4" Male NPT
Dynabrade Air Lube
• Formulated for pneumatic equipment.
• Absorbs up to 10% of its weight in water.
• Prevents rust and formation of sludge.
• Keeps pneumatic tools operating longer
with greater power and less down time.
95842: 1pt. (473 ml)
95843: 1gal. (3.8 L)
96005 Male Plug
• Provides up to twice the air flow
compared to standard plug design.
• Plug has “ported” design to prevent
“starving” of the air tool.
95281 – 19mm open-end wrench.
96148 – 24mm pin wrench
30335 Air Supply Hose
• 3/8 in. I.D. x 60 in. Wide air supply
hose, includes: 3/8 in. NPT male and
female threaded fittings.
95848 Dynabrade Angle Gear Oil
• Specifically formulated to saturate wick system in right
angle gear head.
Bearing Press Tool
• Used to install bearings.
96243: For installing 02057 Bearing.
96244: For installing 01266 Bearing.
95541: Gear Oil Gun
97782 Retainer Repair Tool
• Tool has a 3/8 in. square socket for use with 3/8 in. drive;
breaker bar, ratchet head, or torque wrenches.
Vacuum Hoses and Cuffs
• Used to make proper connection
between tool and vacuum system.
96209 Motor Repair Clamp
• Specially designed clamp to secure motor
cylinder before disassembly.
95800: 1-1/4" Reduction Cuff
54205: Vacuum Hose by the foot.
Note: Please specify length.
Reference Contact Information
1. American National Standards Institute – ANSI
3. European Committee for Standardization
Rue de Stassart 36
25 West 43rd Street
Forth Floor
B - 1050 Brussels, Belgium
New York, NY 10036
Tel: 1 (212) 642-4900
Fax: 1 (212) 398-0023
2. Government Printing Office – GPO
Superintendent of Documents
Attn. New Orders
P.O. Box 371954
Pittsburgh, PA 15250-7954
Tel: 1 (202) 512-1803
Visit Our Web Site: www.dynabrade.com
®
Email: Customer.Service@Dynabrade.com
DYNABRADE
DYNABRADE, INC., 8989 Sheridan Drive • Clarence, NY 14031-1490 • Phone: (716) 631-0100 • Fax: 716-631-2073 • International Fax: 716-631-2524
DYNABRADE EUROPE S.àr.l.,
Zone Artisanale • L-5485 Wormeldange—Haut, Luxembourg • Telephone: 352 76 84 94 1 • Fax: 352 76 84 95 1
© DYNABRADE, INC., 2005
PRINTED IN USA
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