WARNING
1hp Right-Angle Buffer/Polisher
Parts Page Reorder No. PD03•27
Effective July, 2003
Governor Controlled
Air Tool Manual – Safety, Operation and Maintenance
SAVE THIS DOCUMENT, EDUCATE ALL PERSONNEL
Models:
51390
51391
51392
51393
51394
51395
51396
51397
–
–
–
–
–
–
–
–
1,250
1,800
2,800
4,500
1,250
1,800
2,800
4,500
RPM,
RPM,
RPM,
RPM,
RPM,
RPM,
RPM,
RPM,
5/8"-11
5/8"-11
5/8"-11
5/8"-11
M14 x 2
M14 x 2
M14 x 2
M14 x 2
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 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.
SAFETY LEGEND
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 damaged, frayed or deteriorated air hoses and fittings.
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 Buffer/Polishers are ideal for removal and polishing of materials using deburring, cleaning and polishing accessories.
Do Not Use Tool For Anything Other Than Its Intended Applications.
Training: Proper care, maintenance, and storage of your tool will maximize their performance.
• Employer's Responsibility – Provide right-angle buffer/polisher operators with safety instructions and training for safe use of tools and accessories.
Accessory Selection:
• 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. See back page of manual and Dynabrade catalog.
• 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.)
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.
• 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.
• BEFORE MOUNTING AN ACCESSORY, after all tool repairs and whenever a buffer/polisher 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.
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.
• 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 reassembling tool, the right-angle buffer/polisher 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.
• 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 do not create a hazard.
• This tool is rear exhaust. Exhaust may contain lubricants, vane material, bearing grease, and other materials flushed thru the tool.
Report to your supervisor any condition of the tool, accessories, or operation you consider unsafe.
Air System
Regulator
Filter
Lubricator
LUBRICATOR SETTING
1 DROP/MIN.
20 SCFM
90 PSIG
(6.2 Bar)
Air Flow
➤
➤
Closed Loop Pipe System
(Sloped in the direction of air flow)
To Tool Station
Regulator
Refrigerated
Air Dryer
Lubricator
➤
➤
Filter
• 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.
Ball
Valve
➤
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.
Air Flow
Air Tool
Air Compressor
and Receiver
90 PSIG MAX
(6.2 Bar)
Drain Valve
2
Maintenance Instructions
Important: 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: 11411 Air Filter-Regulator-Lubricator (FRL) – Provides accurate
air pressure regulation and two stage filtration of water contaminants. Operates 55 SCFM/1,558 LPM @ 90 PSIG with 1/2" NPT female ports.
• Lubricate wick system through the angle gear oil fitting with 2-3 plunges for every 8 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).
• Grease the planetary gear assembly with the 95542 Grease by applying 2-3 plunges with the 95541 Grease Gun after every 50 hours of use
for maximum gear life.
• 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 right-angle buffer/polisher using a tachometer. This governor controlled right-angle buffer/polisher 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.
• 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 excessive tool vibration.
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 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.
Machine Specifications
Model
Number
Motor
hp (W)
Tool
RPM
Sound
Level
Air Flow Rate
CFM/SCFM (LPM)
Air Pressure
PSIG (Bars)
Spindle
Thread
Weight
Pound (kg)
Length
Inch (mm)
Height
Inch (mm)
51390
1 (746)
1,250
83 dB(A)
6/42 (1,189)
90 (6.2)
5/8"-11
4.8 (2.2)
13-1/8 (333)
3-3/4 (95)
51391
1 (746)
1,800
82 dB(A)
6/42 (1,189)
90 (6.2)
51392
1 (746)
2,800
80 dB(A)
6/41 (1,161)
90 (6.2)
5/8"-11
4.8 (2.2)
13-1/8 (333)
3-3/4 (95)
5/8"-11
4.8 (2.2)
13-1/8 (333)
51393
1 (746)
4,500
79 dB(A)
5/35 (991)
3-3/4 (95)
90 (6.2)
5/8"-11
4.0 (1.8)
11-11/16 (296)
3-3/4 (95)
51394
1 (746)
1,250
83 dB(A)
6/42 (1,189)
90 (6.2)
M14 x 2.0
4.8 (2.2)
13-1/8 (333)
3-3/4 (95)
51395
1 (746)
1,800
51396
1 (746)
2,800
82 dB(A)
6/42 (1,189)
90 (6.2)
M14 x 2.0
4.8 (2.2)
13-1/8 (333)
3-3/4 (95)
80 dB(A)
6/41 (1,161)
90 (6.2)
M14 x 2.0
4.8 (2.2)
13-1/8 (333)
51397
1 (746)
4,500
3-3/4 (95)
79 dB(A)
5/35 (991)
90 (6.2)
M14 x 2.0
4.0 (1.8)
11-11/16 (296)
3-3/4 (95)
Additional Specifications: Air Inlet Thread 3/8" NPT • Hose I.D. Size 3/8" (10 mm) • Air Flow Rate Based At Max HP. • Air Pressure 90 PSIG Max
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.
3
1hp Right-Angle Buffer/Polisher
Index Key
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
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*
52*
53*
54*
55*
Part # Description
50963 Retainer
50899 Seal
53603 Spindle - 5/8"-11
53606 Spindle - M14 x 2
97679 Bearing
97678 Shim
97677 Shim
Gear Set
53639 1,250 and 4,500 RPM
53637 1,800 and 2,800 RPM
53608 Wick
53600 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
51935 Coupling (2)
51936 Coupling Insert
53650 Lock Ring
53651 Spacer
96498 Wave Spring
(2 Needed For Slow Speed)
95438 O-Ring
53620 Adapter
54520 Bearing
(2 Needed For Slow Speed)
04014 Set Screw
01041 Grease Fitting
53695 Gear Casing
53676 Carrier (1,250 - 1,800 RPM)
53669 Carrier (2,800 RPM)
53193 Gear (2) (1,250 - 1,800 RPM)
53195 Gear (2) (2,800 RPM)
04026 Needle Bearing (4)
53679 Shaft (2)
53665 Ring Gear
51951 Shim Pack
51922 Front Bearing Plate
96441 Pin (2)
51927 Spacer
53667 Rotor (1,250 - 1,800 RPM)
53666 Rotor (2,800 RPM)
51921 Rotor (4,500 RPM)
51926 Blade (4/Pkg.)
51925 Cylinder
51923 Rear Bearing Plate
02057 Bearing
96445 Pin (2)
51924 Gasket
Governor Assembly
51932 1,250 RPM Models
51931 1,800 RPM Models
51933 2,800 RPM Models
51643 4,500 RPM Models
All Housings Include:
Warning & Specification Labels
20080 Housing – Model 51390
20081 Housing – Model 51391
20082 Housing – Model 51392
20083 Housing – Model 51393
20084 Housing – Model 51394
20085 Housing – Model 51395
20086 Housing – Model 51396
20087 Housing – Model 51397
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)
Complete Assembly
W1
A8
A8
T
W1
6
35 N•m
8
A
4
2
10
9
A4
7
Description
56 00001180
57 00001181
Warning Label
Specification Label
G1
A8
5
22
20
3
19
1
17
15
13
A10 T
T
T
35 N•m
17 N•m
17 N•m
23
21
13
T
.
Models
RPM
1,800
to
0
5
16
for 1,2
quired
arts re
p
te
a
s indic
d part
Shade
34
32
30
18
14
12
11
7
17 N•m
20
28
26
24
O1
31
33
29
T
13
17 N•m
43
27
25
44
17
2 N•m
36
31
37
T A10
A8
41
57
45
46
42
40
39
38
56
35
hread
and T
Left H
T
35 N•m
55*
O1
52*
47
48*
49*
53*
54*
A10
Note: All index numbers with an asterisk
are included in P/N 53655 Muffler Assembly.
4
KEY
O
Oil: O1 = Air Lube
A
Adhesive: A4 = Loctite #680
A8 = Loctite #567
A10 = Loctite #243
T
Torque: N•m x 8.85 = In. - lbs.
W
Wicking: W1 = Gear Oil
G
Grease: G1 = Lubriplate 630 AA
51*
50*
Label Key
No. Part #
C
B
Disassembly Instructions - 1hp Right-Angle Buffer/Polisher
Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires.
Disconnect tool from power source before tool repair.
Right Angle Head Disassembly:
1.
2.
3.
4.
5.
6.
7.
8.
Remove side handle and polishing pad.
Secure 53600 Right Angle Housing, against both side handle bosses, in a padded vise with spindle facing upward.
Using 97782 Pin Wrench (ordered separately) or an adjustable pin wrench, remove 50963 Retainer. (Left Hand Threads)
Remove 50899 Shaft Seal from retainer.
Pull spindle and gear assembly from housing.
Press spindle through 97679 Bearing and spiral bevel gear.
Remove shims and 53608 Wick from right angle housing.
Remove 53650 Lock Ring from right angle housing (Left Hand Threads) and from 53695 Gear Casing (Right Hand Threads). Note: For 4,500 RPM models, remove
lock ring from motor housing (Right Hand Threads).
9. Remove angle head from vise and remove 96325 Bearing by pressing 53649 Gear Oil Plate through housing.
10. Pull pinion gear, bearing and coupler sub-assembly from angle housing.
11. Secure gear, bearing and coupler sub-assembly by the pinion gear wrench flats and remove the 51935 Flexible Coupler (twist counterclockwise).
12. Secure 53635 Adapter using an allen wrench and remove pinion gear (twist counterclockwise).
13. Press 53635 Adapter through 01266 Bearing.
Note: For 4,500 RPM models, omit steps 14 through 17.
14. Remove 04014 Set Screw from 53695 Gear Casing and remove gear casing (Right Hand Thread) from motor housing.
15. Slide 53665 Ring Gear from gear casing.
16. Secure planetary carrier using 53698 Wrench (ordered separately) and remove 51935 Coupling (twist counterclockwise).
17. Press planetary carrier thread end through 54520 Bearing.
18. Remove 96498 Wave Spring.
19. Press 53679 Pins from carrier to remove gears.
Right Angle Head Disassembly Complete.
Motor Disassembly:
1.
2.
3.
4.
5.
Remove 53651 Spacer and 96498 Wave Spring from housing assembly.
Pull motor assembly from housing.
Remove 53620 Motor Adapter with 95438 O-Ring. Note: Step 3 applies to 4,500 RPM models only.
Remove governor assembly by using a slotted screwdriver. (Left Hand Thread)
Secure 51925 Cylinder using 96209 Motor Repair Clamp (ordered separately) and place a 1/8" (3 mm) drift pin to the base of the terminal thread and press 51921 Rotor
from the 02057 Rear Bearing.
6. Slide 02057 Rear Bearing from 51923 Rear Bearing Plate.
7. Remove 51925 Cylinder and 51926 Blades.
8. Secure 51921 Rotor in a padded vise and remove 51935 Extension Coupler (twist counterclockwise). Note: Steps 8 applies to 4,500 RPM models only.
9. Press rotor through 54520 Bearing, 51922 Front Bearing Plate and 51927 Rotor Spacer.
10. 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" (3 mm) 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 - 1hp Right-Angle Buffer/Polisher
Motor Assembly:
Important: Be sure parts are clean and in good repair before assembling. Follow grease, oil and torque specifications.
1. Place rotor into a padded vise with gear teeth or 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" 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" and .002" 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 51935 Coupler into place (Torque to
17 N•m 150 lb.-in.). Note: Step 5 applies to 4,500 RPM models only, omit step 6.
6. Press Bearing/Bearing Plate assembly onto rotor.
7. Check clarence between rotor and front bearing plate by using a .001" feeler gauge. Clarence should be between .001" – .0015". Adjust clarence by repeating steps 4,5
and 6 with different shims if necessary.
8. Once proper rotor gap clarence is achieved, install well lubricated 51926 Blades (4) into rotor slots. Dynabrade recommends lubricating blades with 95842 Air Lube.
9. Install 51925 Cylinder over rotor and front plate raised boss. Align coiled pin on front plate to cylinder slot.
10. 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.
11. Peel backing off 51924 Gasket and apply it firmly in place onto 51923 Rear Bearing Plate.
12. 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 lines up with inlet slot on cylinder. To correct alignment flip cylinder end to end and repeat step 9 for correct assembly.
13. 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.
(continued on next page)
Assembly Instructions - (Continued)
Important: Manufacturer’s warranty is void if tool is disassembled before warranty expires.
Please refer to parts breakdown for part identification.
14. Add one drop of Loctite® 243 (or equiv.) to governor assembly male thread and screw governor assembly into place (Left Hand Thread) with slotted screw head.
Torque to 2 N•m (18 lb.-in.).
15. 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.
Motor Assembly Complete.
Right Angle Head Assembly:
1. Press 01041 Gear Oil Fitting into 53649 Gear Oil Plate. Apply a drop of Loctite #680 (or equivalent) to the diameter of the 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 to contact outer race
of bearing only.
3. Add one drop of Loctite® #243 (or equiv.) to male thread of 53635 Adapter and tighten pinion using a 3/16" Hex Key wrench and the pinion wrench flats.
Torque to 17 N•m (150 lb.- in.).
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 51935 Coupler using wrench flats. Torque to 17 N•m (150 lb.- 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).
Note: For 4,500 RPM models, omit steps 8 through 18, go to step 19.
8. Install 53665 Ring Gear over 54520 Front Motor Bearing, keeping 2 slots facing outward.
9. Install gears with needle bearings and assemble onto planetary carrier by pressing retainer shafts into place.
10. Place 96498 Wavy Washer at the base of 53695 Gear Casing female threaded end.
11. Slide planetary carrier assembly, with threaded end first, into 53695 Gear Casing and through 54520 Bearing.
12. Apply one drop of Loctite® #243 (or equiv.) to threads of 51935 Coupling. Secure planetary carrier using 53698 Wrench (order separately) and thread on 51935 Coupling
(twist clockwise). Torque to 17 N•m (150 lb.-in.).
13. Apply a small amount of Loctite® #567 (or equiv.) to male thread of motor housing and thread 53695 Gear Casing over ring gear and onto motor housing. Important: Align
rotor spline into planet gears to allow carrier to spin freely.
14. When slots from ring gear line up with set screw hole, apply a small amount of Loctite® #567 (or equiv.) to male thread of 04014 Set Screw, and install set screw to lock
ring gear in place.
15. Torque 53695 Gear Casing to 35 N•m (310 lb.-in.).
16. Place 51936 Coupling Insert into 51935 Coupling. Make certain insert radii in coupling base, to correct alignment remove insert and rotate 90˚.
17. Secure 53600 Right Angle Housing, against both side handle bosses, in a padded vise.
18. Rotate motor housing/gear casing and 53650 Lock Ring until throttle lever is located between the 9-11 o'clock position. Throttle lever in this position safe guards against
accidental start ups of the tool. Torque lock ring to 35 N•m (310 lb.-in.).
Note: Steps 19 through 26 apply to 4,500 RPM models only, for all other models go to step 27.
19. Install 95438 O-Ring onto 53620 Adapter and slide adapter into housing and over 54520 Bearing.
20. Place 96498 Wave Washer onto 53620 Adapter.
21. Place 51936 Coupling Insert into 51935 Coupling. Make certain insert radii in coupling base, to correct alignment remove insert and rotate 90˚.
22. Insert 53651 Spacer, with short length first, into 53650 Lock Ring and up against 01266 Bearing.
23. Apply a small amount of Loctite® #567 (or equiv.) to male thread of motor housing.
24. Align 51936 Coupling Insert into 51935 Coupling in right angle head assembly and thread motor into 53650 Lock Ring (twist clockwise).
25. Secure 53600 Right Angle Housing, against both side handle bosses, in a padded vise.
26. Rotate motor housing and 53650 Lock Ring until throttle lever is located between the 9-11 o'clock position. Throttle lever in this position safe guards against accidental start
ups of tool. Torque lock ring to 35 N•m (310 lb.-in.).
27. 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.
28. Press 97679 Bearing onto spindle and against shoulder. Important: While pressing 97679, make certain to contact inner race of bearing only.
29. Press gear, with teeth facing away from bearing, into spindle and against 97679 Bearing inner race.
30. Insert spindle assembly into 53600 Right Angle Housing until 97679 Bearing contacts housing shoulder.
31. 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 clarence throughout 360˚ revolution).
32. Press 50899 Shaft Seal into 50963 Retainer with base of seal facing outward.
33. Apply a small amount of Loctite® #567 (or equiv.) to the male thread of the retainer and thread into place. (Left Hand Thread)
34. Using 97782 Pin Wrench (ordered separately) or an adjustable pin wrench, torque retainer to 35 N•m (310 lb.-in.).
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 lb.- 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.
Loctite® is a registered trademark of Loctite Corp.
Preventative Maintenance Schedule
For All 1hp Right-Angle Buffer/Polishers
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 included in motor tune-up kit are identified
by items marked with a "T".
Parts Common to all Models:
LEGEND
T
Part included in 96532
Tune-up Kit
X
Type of wear, no other
comments apply.
L
Easily lost. Care during
assembly/disassembly.
D
Easily damaged during
assembly/disassembly.
R1 Replace each time tool is
disassembled.
R2 Replace each second
time tool is disassembled.
96532 – 1hp. Motor Tune-Up Kit
• Tune-Up Kit includes high wear
and medium wear motor parts.
Index Part
# Number
1 50963
2 50899
3 See Pg.4
4 97679
5 97678
6 97677
7 See Pg.4
8 53608
9 53600
A 96325
B 53649
C 01041
10 53163
11 01266
12 53635
13 51935
14 51936
15 53650
16 53651
17 96498
18 95438
19 53620
20 54520
21 04014
22 01041
23 53695
24 See Pg.4
25 See Pg.4
26 04026
27 53679
28 53665
29 51951
30 51922
31 96441
32 51927
33 See Pg.4
34 51926
35 51925
36 51923
37 02057
38 96445
39 51924
40 See Pg.4
41 See Pg.4
42 96444
43 51949
44 51946
45
46
47
48
49
50
51
52
53
54
55
51945
51944
51943
96442
51940
53682
94528
53686
94924
53683
53681
Description
Number High Wear Medium Wear Low Wear
Required
100%
70%
30%
Retainer
1
Seal
1
R2
Spindle
1
Bearing
1
X
Shim
1
Shim
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
Coupling
2
Coupling Insert
1
X
Lock Ring
1
Spacer
1
Wave Spring
1
T, L
O-Ring
1
Adapter
1
Bearing
1
T, X
Set Screw
1
L
Grease Fitting
1
X
Adapter
1
Carrier
1
X
Gear
2
X
Needle Bearing
4
X
Shaft
1
X
Ring Gear
1
X
Shim Pack
1
T, L
Front Bearing Plate
1
X
Pin
2
X
Spacer
1
T, X
Rotor
1
X
Blade (4/pkg.)
1
T, X
Cylinder
1
X
Rear Bearing Plate
1
X
Bearing
1
T, X
Pin
2
X
Gasket
1
T, X
Governor Assembly
1
Housing
1
Pin
1
T, L
Safety Lever Assembly
1
X
Valve Stem Assembly
1
T, X
(Includes 96443 O-Ring)
Valve Seat
1
Tip Valve
1
T, X
Spring
1
O-Ring
1
T, L
Spacer
1
Gasket
1
Felt Silencer
1
T, R1
Muffler Cap
1
Wave Spring
1
Spacer
1
Inlet Bushing
1
(Incl. 2 – 51938 Screens)
7
Non-Wear
10%
X
X
X
X
X
X
X
X
X
X
X
X
T, X
X
X
X
X
X
X
X
X
X
X
X
X
Optional Accessories
®
96532 Motor Tune-Up Kit
• Includes assorted parts to help maintain
and repair motor.
01902 Drop-In Motor - 4,500 RPM
01904 Drop-In Motor - 2,800 RPM
01905 Drop-In Motor - 1,250 - 1,800 RPM
• Allows quick and easy replacement.
No motor adjustments needed.
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.
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)
53621 Over Hose Assembly
• Over Hose Assembly directs exhaust
away from operator.
Bearing Press Tool
• Used to install bearings.
96243: For installing 02057 Bearing.
96244: For installing 01266 Bearing.
53698 Carrier Wrench
• Carrier Wrench has a 3/8 in. square socket
for use with 3/8 in. drive; breaker bar,
ratchet head, or torque wrenches.
Dynabrade Angle Gear Oil
• Specifically formulated to saturate wick system in right
angle gear head.
95848: 2 oz. tube
95849: 10 oz. tube
95541: Push-Type Gear Oil Gun
95542 Grease 10 oz.
• Multi-purpose grease for all types of
bearings, cams, gears.
• High film strength; excellent resistance to
water, steam, etc.
• Workable range 0˚ F to 300˚ F.
95541 Push-type Grease Gun
• One-hand operation.
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.
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.
6" Disc Pads (3,200 RPM Max.)
50828 (5/8"-11) - Foam-Backed Rubber-Face
Soft Pad for PSA.
57545 (5/8"-11) - Hook-Face Pad for
Reattachable Discs.
96209 Motor Repair Clamp
• Specially designed clamp to secure motor
cylinder before disassembly.
7-1/4" Disc Pads (3,200 RPM Max.)
50853 (5/8"-11) - Hook-Face Pad for
Reattachable Discs.
50854 (M14x2) - Hook-Face Pad for
Reattachable Discs.
95263 – 17 mm open-end wrench.
95281 – 19 mm open-end wrench.
53209 Ergo-Handle
• Increases operators comfort when
using unbalanced wheels.
8" Disc Pads (3,200 RPM Max.)
50829 (5/8"-11) - Foam-Backed Rubber-Face
Soft Pad for PSA.
50947 (5/8"-11) - Hook-Face Pad for
Reattachable Discs.
50984 Top Handle Assembly
Reference Contact Information
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, 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., 2006
PRINTED IN USA
PD03.27_Rev.1_08/06
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