Dynabrade 48201, 48203, 48325, 48327, 48341 Safety, Operation And Maintenance Manual
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Parts Page Reorder No. PD11•26
Supersedes PD10•04
Effective July, 2011
.4 hp Die Grinder
Ergo-Grip - Rear Exhaust
Air Tool Manual – Safety, Operation and Maintenance
Read and understand tool manual before
work starts to reduce risk of injury to
operator, visitors, and tool.
Eye protection must be worn
at all times, eye protection to
conform to ANSI Z87.1.
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.
SAVE THIS DOCUMENT, EDUCATE ALL PERSONNEL
SAFETY LEGEND
G
Ear protection to be worn when exposure to sound,
exceeds the limits of applicable Federal, State or
local statues, ordinances and/or regulations.
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.
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.
Practice safety requirements. Work alert,
have proper attire, and do not operate tools under
the influence of alcohol or drugs.
FIND THE MOST CURRENT OFFERING OF SUPPORT DOCUMENTS AND ACCESSORIES AT WWW.DYNABRADE.COM
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.
Tool Intent: .4 hp Die Grinder is ideal for deburring, deflashing, surface preparation, cleaning and finishing using the proper abrasive stones, abrasive
mounted wheels, molded abrasives, and carbide burrs.
Do Not use tool for anything other than its intended applications.
This power tool is not intended for use in potentially explosive atmospheres and is not insulated against contact with electrical power.
Training: Proper care, maintenance, and storage of your air tools will maximize their performance.
• Employer's Responsibility – Provide .4 hp Die Grinder operators with safety instructions and training for safe use of tools and accessories.
(continued on next page)
Model 48327
Model RPM Collet Style Muffler Insert Size
48201
25,000 3 Piece Extended 1/4" & 6 mm
48203
30,000 3 Piece Extended 1/4" & 6 mm
48325
25,000 3 Piece Standard 1/4" & 6 mm
48327
30,000 3 Piece Standard 1/4" & 6 mm
48341
30,000 3 Piece Overhose 1/8" & 3 mm
48345
30,000 4 Piece Standard 1/8" & 3 mm
48350
35,000 3 Piece Extended 1/8" & 3 mm
48355
35,000 3 Piece Extended 1/4" & 6 mm
48360
20,000 3 Piece Standard 1/4" & 6 mm
48365
20,000 4 Piece Standard 1/8" & 3 mm
48370
25,000 4 Piece Standard 1/8" & 3 mm
WARNIN
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
2
SAFETY INSTRUCTIONS
(Continued)
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 accessories of the correct shaft size for the collet (example: 1/4" shaft = 1/4" collet).
• 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) or 150 percent of the maximum pressure produced in the system, whichever is higher. (See tool Machine Specifications table.)
OPERATING INSTRUCTIONS
Warning: Always wear personal protective equipment. 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.
• Working end of tool has a potential of cutting and severing.
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 .4 hp Die Grinder 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. Improper mounting of an accessory may cause excessive vibration levels or damage the accessory. Make sure no one is in the
unguarded plane of the accessory. Run tool for 1 minute of operating speed in a protected area.
• Connect air tool to power source. Be careful NOT to depress throttle lever in the process. Do not expose air tool to inlet pressure above 90 PSIG or (6.2 Bars).
Caution: After installing the accessory, before testing or use and/or after assembling tool, the .4 hp Die Grinder 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. Test tool at
its free speed (RPM) in a protected area for at least one minute before applying the tool to the work.
• Release throttle lever when air supply is interrupted.
• 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 does not create a hazard.
• Tool is rear exhaust, exhaust may contain lubricants, vane material, bearing grease, and other materials flushed thru the tool.
Warning: Grinding certain materials can create explosive dust. It is the employers responsibility to notify the user of acceptable dust levels.
• Grinding can cause sparks which can cause fires or explosions. It is the users responsibility to make sure the work area is free of flammable materials.
• DO NOT USE cut-off wheels or router bits on this tool.
• Always use dust extraction or suppression systems and personal protective equipment which are suitable for the materials being processed.
Report to your supervisor any condition of the tool, accessories, or operation you consider unsafe.
PROPER MOUNTING PROCEDURE
With Power Source Disconnected from the Tool, Mount Recommended Accessory
Collet Cap
Burr/Mounted Wheel
Collet Insert
Collet Body
Mount Wheel/Burr Mandrel
Fully Inserted into Collet Insert.
Excessive Overhang Reduces Bit MOS,
Refer to ANSI B7.1 Standards
Note: Intended for general
reference use only. Always refer
to ANSI B7.1, B186.1 and EN
792 for detailed requirements.
Bit Gripping Length: Bit should be
inserted no less than 1" (13mm) into
the collet insert.
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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 ensure 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 Line Filter-Regulator-Lubricator — Provides accurate air
pressure regulation, two-stage filtration of water contaminants and micro-mist lubrication of pneumatic components. Delivers up to 55 SCFM/1,558 LPM
@ 145 PSIG/9.7 Bar (Max. Air Temperature of 140˚F/60˚ C) Note: Two (2) 3/8" NPT Reducer Bushings are included.
•
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.
Specific Routine Preventative Maintenance - 20,000, 25,000 and 30,000 RPM Governed Tools: Check free speed tool using a tachometer without accessory
mounted. This governor controlled die grinder should be speed checked every 20 hours of use or weekly, whichever occurs more frequently after maintenance or repair.
•
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.
Specific Routine Preventative Maintenance - 35,000 RPM Non-Governed Tools:
•
Check free speed of tool regularly using a tachometer without the abrasive accessory mounted. After all tool repairs and whenever a .4 hp Die Grinder 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, operating improperly or demonstrates unusual vibration, the tool must be serviced and corrected before use.
Routine Preventative Maintenance
•
Inspect accessories before mounting. Do not mount accessories that are damaged or nicked.
•
Check accessory - speed rating. Rating on accessory must be greater than the tool speed marked on the housing.
•
If accessory breakage 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 96541) is available which includes high wear and medium wear motor parts.
•
Air tool markings must be kept legible at all times, if not, reorder housing 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 tool inlet 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 on Page 7).
•
DO NOT carry tool by air hose or near the tool throttle lever.
•
Protect accessories from exposure to water, solvents, high humidity, freezing temperature and extreme temperature changes.
•
DO NOT USE accessories that have been dropped or show signs of cracks, nicks or other defects.
•
Store accessories in protective racks or compartments to prevent damage.
3
Air System
Filter
Regulator
Lubricator
90 PSIG
(6.2 Bar)
To Tool Station
Closed Loop Pipe System
(Sloped in the direction of air flow)
Ball
Valve
Ball
Valve
Filter
Regulator
Lubricator
Air Flow
Drain
Valve
Drain
Valve
Air Tool
Air Compressor
and Receiver
Drain Valve
Air Hose
90 PSIG MAX
(6.2 Bar)
Air Flow
Refrigerated
Air Dryer
1 DROP/MIN.
20 SCFM
LUBRICATOR SETTING
•
Dynabrade Air Power Tools are designed to operate at
90 PSIG (6.2 Bar) maximum air pressure at the tool inlet,
when the tool is running. Use recommended regulator
to control air pressure.
•
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.
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